Tendernotice 4

SCHEDULE I
SCOPE OF WORK
The Scope of Work for the Project will, inter-alia, be divided into the following Packages -
A. Design, finance, development, construction, completion, 15 years operation and maintenance
I. Saharanpur Facilities -
i. Saharanpur STP Facilities of 135 MLD at Pinjora village
ii. Saharanpur Associated Infrastructure includes
(a) I&D structures for diversion of flow from drains/nallas to interceptor sewer line and
sewage pumping stations (SPS),
(b) Interceptor gravity sewer,
(c) Connectivity of proposed gravity sewer with existing sewage pumping stations,
(d) Crossing of sewer line across the river Damola and Paodhoi,
(e) connectivity of sewer with the MPS at STP site,
(f) Rising main from SPS/MPS to STP,
(g) connectivity of sewer/rising main from 38 MLD existing STP (Praduman Nagar) with
MPS and STP
(h) construction of approach road to STP,
(i) cleaning and overhauling of existing I&D facilities
(j) integration of existing I&D facilities with the proposed I&D facilities
(k) restoration of road, any existing structures/assessts which are demolished during
execution of work,
(l) co-treatment of septage in the STP, and
(m) other allied/associated works etc.
iii. 15 years operation and maintenance of Saharanpur STP Facilities of 135 MLD at Pinjora
village and Associated Infrastructure
The Concessionaire shall plan to undertake such works for Saharanpur as per the provisions of the
Concession Agreement and in adherence to the applicable Key Performance Indicators mentioned in
Schedule 9.
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Point A: Scope of Work related to the Designing, financing, development, construction, completion,
15 years operation and maintenance of the Saharanpur Sewerage Scheme which will include the
following components –
A1 - Undertake the following work in relation to the proposed 135 MLD Saharanpur STP Facilities
to an Average flow of 135 MLD (year 2038) (for E&M works) and 172.30 MLD (year 2053) (for
Civil works) on Saharanpur Site.
Design, finance, development, construction, testing & commissioning of all civil, mechanical, electrical &
instrumentation works of Saharanpur STP with a design capacity of average flow of 135 MLD, at
Saharanpur, Saharanpur STP Site. The Saharanpur STP shall, inter-alia, include provision of the following
components, the online monitoring system to measure the volume and characteristics of the Sewage
conveyed to the Saharanpur STP Site and the volume and characteristics of treated effluent discharged from
the Saharanpur STP, on-site testing laboratory facilities, sludge management and any other facility
associated with the operations of the Saharanpur STP. Refer the Schedule 11 for Tentative layout and
survey details.
Provide the following at Saharanpur STP:

i. Cleaning and dewatering of STP site, survey of the area, fixing bench mark (with GPS Coordinate),
coordinates, soil test as per design requirements, collection of latest river data and HFL, identification
of inlet point and outfall of the STP. (The land for proposed STP is a water logged area and saturated
soil has been found at the top. The cleaning activities refer to removal of marshy soil and removal of
bushes and shrubs from the proposed STP premises)
ii. Construct brick masonry boundary wall/river bank protection works with RCC framework consisting
of retaining wall/diafram wall/ curtain wall, columns and beams and footings around the Saharanpur
STP Site with barbed wire fencing above brick masonry boundary wall with gate and guard room.
 Construct brick masonry boundary wall of 1.8 m height, with RCC framework consisting of
columns and beams and footings around the Meerut STP Site with barbed wire fencing
(concertina wire of spiral 600 mm diameter) above brick masonry boundary wall, with gate
and guard room. Indicative length of boundary wall is 1600 meter
 River bank protection: Gabion wall need to be construct for river bank protection. A total of
approximate 1000 m length need to be covered and is of approximate 12000 m3 quantity.
iii. Internal drainage system, site development works, rain water harvesting for building roof tops,
internal roads within the compound of the Saharanpur STP Site, entry gate, guard room, vehicle
parking shed.
iv. Landscaping & horticulture to be well maintained at STP Plant in balance of area within the
compound of the Saharanpur STP Site.
v. The proposed new STP land is low lying area and has large potholes due to carrying of soil by the
local people. The land filling and leveling of site shall be with in the scope of project, no additional
cost will be given. The approach road to site is from the residential area for which alternate root has
to be constructed.
vi. Construction of approach road shall be included in point (i). Survey of existing road for access to
STP site, use of CC (M30) for pavements and according to UPPWD’s design and norms for heavy
load vehicles use.
Approach Road: Approach road from Existing STP of length 250 m and 5.5 m width between
the polishing ponds of existing STP to be constructed along with a box culvert of 20 m length
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and suitable depth as per flow and 300 m approach road from entry gate of existing STP to
polishing ponds.
vii. Potable water supply arrangement within STP including OHT, tube well etc. for admin building, staff
quarters and process requirement. Construct a two-storied administrative building of 150 m2 built up
area on each floor which shall be include a laboratory, conference room (25 seating capacity with
projector and internet facility) etc. (as per CPHEEO manual and applicable standards).
Administrative building shall be completed within 2nd milestone.
viii. Architecture of Admin and other buildings should be aesthetically designed facades, texture painting
and in line with local heritage.
ix. Construct a site office (for executive engineer, assistant engineers, site engineers and one common
meeting room) with all necessary equipment, computers, printers and staff them adequately, which
can also be used by the UPJN. The office should be developed for a minimum capacity of 4 persons
independently.
x. Construct staff quarters including necessary facilities such as toilet facilities, potable water and
electrification etc. as per UPJN’s standards. Staff quarters with size and FSI as per the CPWD norms
provided in "Revised Plinth Area Norms for General Pool Residential Accommodation (GPRA) to
be constructed for Govt. Employees. (G+2 structure) 3 No. Type II and 1 Nos. Type III with
provision for extending these up to next storied.
xi. Mechanical items like pumps, motors, fine screen, grit remover, blower (with acquoistic arrangement
to bring noise level at 45db, accordingly blower room to be kept away from away from admin block
and also maintain the noise level at STP Boundary is 45 db(A) in day time and night time), pipe,
scrapper, penstock gate, valves etc., shall be provided as per design requirements. All equipment shall
be SCADA compitable.
xii. High speed centrifugral blower or turbo blower shall be acceptable for high efficiency and low
electricity consumption. The noise level (dBA) with Acoustic Enclosure should be less than 45 dB.
Measurement of ambient norms shall be done at 1 meter within the boundary wall.
xiii. Internal and external electrification and illumination of the STP and its facilities as per applicable
guidelines/codes.
xiv. To provide Electrical equipments, electrical transformers, switch gears, control panel, busbar, DG
set, earthing system, lightening protection system etc. as per standards and specifications.
xv. Installation of CCTV and required accessories, lightening protection system, earthing system for
buildings and key structures.
xvi. Complete automation (with SCADA) of STP including all necessary instrumentation as per process
requirement including LCS to communicate with Saharanpur Associated Infrastructure to collect,
store, process the data received from I&D works, MPS, STP and to transmit the same to MCS at
UPJN office, Saharanpur. LCS and MCS shall also provide control operations to the above mentioned
Facilities. All operation shall be facilitated with HMI. OCEMS shall be considered in the facilities.
xvii. Biogas generation system including biogas collection system, biogas holder, conveyance network,
gas flaring, heating system, and allied works as applicable.
xviii. Fire-fighting system with firewater pipe network and fire-fighting arrangements including fire alarm
system.
xix. Disinfection facility for treated effluent. Safety precaution for disinfection system shall be provided.
xx. Disposal of treated effluent
Treated effluent from the Saharanpur STP will be disposed into river Dhamola including
provision for withdrawal arrangement (by gravity with proper control gate arrangment) for
reuse of treated effluent such as for irrigation purpose etc.
xxi. Co-treatment at 135MLD sewage treatment plant (STP) to handle 50 KLD of Septage. All necessary
civil and electromechanical items and all standard accessories must be installed by the concessionaire.
And carry out operation and maintenance for the concession period.
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xxii. Sludge Management System should have a separate entry/exit and it should be separately kept away
from the main entrance gate and Admin block.
xxiii. Outfall of treated discharge in River should be with some architectural feature, for example- waterfall
in staircase or stone form etc.
xxiv. Freeboard for all the hydraulic structures should be minimum 0.5 meter (specially in PTU).
xxv. The Concessionaire need to install live operated CCTV camera on STP site with
xxvi. Biogas Production and Supply
(a) Digester, Gas holding system and gas flaring unit construction shall be in scope of concessionaire.
The concessionaire has to generate bio gas. However, the concessionaire shall have no right on the
biogas produced and shall not take any credit for power generation while quoting for guaranteed
power consumption for the plant/ STPs. The design of sludge handling system and digester shall
be as per CPHEEO manual. Sludge handling system shall be designed for primary and secondary
sludge. The gas storage system shall be equipped with storage capacity of at least 50% of the total
daily gas production. Biogas flare shall be provided for gas flaring purpose. The concessionaire
shall provide an outlet gas pipeline from gas storage unit till the battery limits of the Compressed
Bio Gas (CBG) facility/ bottling plant.
(b) The biogas generation and harnessing potential is required to be maximized. The minimum quantity
of biogas to be generated shall be 70 m3 of biogas per MLD of incoming sewage. System has to be
designed in such a way to generate and handle maximum biogas and to minimize emission of
greenhouse gases in accordance with approved process design by Jal Nigam. The entire quantity of
gas produced by the concessionaire shall be delivered to the CBG facility.
(c) The process of purification, compression and bottling shall not be in the scope of concessionaire,
which may be carried out by Indian Oil Corporation Limited (IOCL), or any othe suitable agence
identified by NMCG/UP Jal Nigam. Biogas produced through the process of anaerobic
decomposition will be purified by IOCL to remove hydrogen sulphide (H2S), carbon dioxide
(CO2), water vapor and compressed to produce CBG. The CBG shall be handled by 'SATAT’
scheme (Sustainable Alternative Towards Affordable Transportation) launched by Ministry of
Petroleum & Natural Gas on 1.10.2018 through separate mechanism.
(d) Space requirement for CBG Facility: Plot of approximately 30m X 30m land is earmarked for
setting up the CBG facilities which includes Purification units, Compressors and cascades, near to
the gas storage facility, while conceptualizing/ laying out the STP facilities during the design. The
concessionaire shall design the STP facilities accordingly.
xxvii. Soil erosion control measures at proposed stp site

Since the proposed STP land is low lying area and on the river bank of river Dhamola. The
Concessionaire shall construct proper flood control structures (stone pitching) in consulation with
Water resource department/ Irrigation and their approval of design for stability of riverbank. The
scope of work shall also include prevention of soil erosion beyond the riprap wall for at least 30 to
40 meters by planting vegetation and trees etc., suitable for stopping the erosion of soil, subject to
availability of land.
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A2 - Undertake the following in relation Associated Infrastructure i.e. Main pumping Station in
Same Premise of Saharanpur STP.
Design, finance, development, construction, testing & commissioning of all civil, mechanical,
electrical & instrumentation works of at Dhamola river MPS. Refer the Schedule 11 for Tentative
layout and survey details.
Provide the following as part of MPS average flow of 135 MLD (year 2038) (For E&M works)
and 172.30 MLD (year 2053) (For Civil works)
i. Cleaning and dewatering of MPS site, survey of the area, fixing bench mark, coordinates, soil
test as per design requirements, collection of latest river data and HFL, identification of inlet
point and outlet from MPS and discharge point at STP through a rising main with adequate
capacity for 2053 flow.
ii. Non-clog sewage submersible/dry-well non-clog horizontal centrifugal type pumps with motor
of following configuration:
Number of working and standby pumps as per design discharge, head, rpm, shall be provided
with VFD, auto couplings, side guide rail system, piping including by-pass arrangement and
common header, actuator operated sluice/ knife gate valves, non-return valves, dismantling
joints, fittings, specials, lifting & hoisting arrangement (EOT), tools, safety equipment and
other allied accessories.
iii. Provisions in civil structure, electrical, mechanical and instrumentation work shall be based on
type and configuration selected from the above.
iv. HT&LT panels, switch gears, equipment, control panels, APFC panel, soft starters/VFD
electric transformers, DG sets with AMF with 100% back up for STP Operations during power
failure, internal & external electrification & illumination, power wiring and control wiring,
lightening protection system, earthing system, ventilation arrangement and other allied works.
v. Complete automation (with SCADA) of Saharanpur at Dhamola river MPS with
electromagnetic flow meter, level transmitters, pressure transmitter, PLC and allied works.
vi. Mechanically cleaned medium bar screen (coarse screen) with manually cleaned medium bar
screen as standby, actuator operated sluice gates, ventilation arrangements.
vii. Internal drainage system, site development works, internal roads, rain-water harvesting within
the compound of the Saharanpur at Dhamola river MPS Site.
viii. Firefighting system including Fire alarm system shall be provided at the MPS as per CPHEEO
manual Part B and UP State Government firefighting rules and regulations revised from time
to time. The Jal Nigam will seek suitable approvals from local fire & safety officers as per the
proposal submitted by the concessionaire.
A3 - Undertake the following in relation to Saharanpur Associated Infrastructure i.e. Rising main
from Dhamola river MPS to Saharanpur STP.
Design, finance, development, lowering, laying, testing & commissioning of rising main of class DI K-9
pipeline of 1600 mm diameter and approximately 50 m in length from Dhamola river MPS to Saharanpur
STP. Refer the Schedule 11 for Tentative layout and survey details. In case of rising main, Box culvert
proposed for Dhamola river crossing. The box culvert proposed at approach road in between the existing
polishing pond has to be used as river crossing for rising main.
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A4- Undertake the following in relation to Saharanpur Associated Infrastructure i.e. Interception
Sewer network.
Design, finance, development, lowering, laying, testing & commissioning of Interception Sewerline
network of class RCC NP3 pipeline of various diameter and length as given below to connected the all of
Proposed I&D Nala tapping to Dhamola River MPS. Refer the Schedule 11 for Tentative layout and survey
details.
Details of sewer Network
S.No Diameter Length (meter) Material of Pipe

(mm)
1. 300 1465
2. 350 2550
3. 400 670
4. 500 2445
5. 600 2430
6. 800 2400 RCC NP4
7. 1200 610
8 1400 1050
9 1600 2380
Total 16000
Interceptor sewer shall be laid on the left & right banks/bed of River Dhamola and left bank/bed of River
Paondhoi and shall be protected from all type of damages as per site condition. Sewerage network shall be
designed after survey and necessary geotechnical investigation.
Railway and road crossing proposals shall be submitted by the concessionaire as per the requirements of
the respective departments; it is responsibility of the Concessionaire to follow up for further permissions,
Jal Nigam will provide the necessary support for liasoning with the concerned departments.
RCC NP-4 pipes shall be used when sewers are being laid below the river bed or drains, further
Concessionaire shall carryout design checks with respect to loading on pipes.
A5 - Undertake the following in relation to Saharanpur STP Facilities and its Associated
Infrastructure
Design, finance, development, construction, testing & commissioning of civil, mechanical, electrical &
instrumentation works for Interception & Diversion Structure which shall include remodelling of drain,
weir, tapping structure, screens, intercepting sewers of indicative lengths as described in the Information
Memorandum and diameter of which shall be as per CPHEEO norms at below drains in the tabular form.
Design, finance, development, construction, testing & commissioning of civil, mechanical, electrical &
instrumentation works for below mentioned Drains works which shall include weir, screens, flowmeter
with accessories, gate and tapping structure for diverting flow to nearest chamber/pumping station through
sewerlines of indicative lengths as described in Annexure Q to the Information Memorandum and diameter
of which shall be as per CPHEEO norms. Concessionaire to ascertain the alignment.
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Tentative
S. No. Location Name of drain flow (in
MLD)
1 Jawahar nagar khurana niwas* 0.64
2 Swami dental clinic* 0.5

3 Near Janak hotel* 1
4 Braj Transport* 8.73
Paondhoi left side
5 Khumranpulmandike pass* 0.75
drains
6 Sharab theka ke samne* 0.73
7 Natraj drycleaners* 0.45
8 Ram tirath school Drain (left side of Paondhoi)* 0.58
9 Kotwali nalla* 0.45

10 Chilkana nalla (Dhobi ghat) * 17.41
11 Paondhoi right side from from Dhobighat IPS* 3.57
12 Agarwal Daramshala-1* 0.15
13 Agarwal Daramshala-2* 0.7
14 Baghat singh chowk ke samne* 0.25
Paondhoi right
15 Kumranpul riksaw stand* 0.5
side drains
16 Dalmandi Pumping station* 0.44
17 Ansari road near Dr. neha clinic* 0.29
18 Machhli bajar* 0.61
19 Jogiyan pul near ganpati cellphone* 0.58
20 Near taj nalla* 0.13
21 Janta colony* 0.04
22 Numaish camp V shape nalla* 0.7
23 Dukhibagh* 0.06
24 Shanti nagar-1* 0.02
25 Shanti nagar-2* 0.26
26 Bijlighar nalla* 0.7
27 Dhamola left side Beribagh drain* 0.5
28 before confluence Nalla near Irrigation land* 0.04
29 Nand vihar* 0.23
30 Nand vatika-1* 0.17
31 Nand vatika-2* 0.01
32 Abdullah colony* 0.21
33 Badshai masjid* 0.07
34 Nai basti-1* 0.03
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35 Nai basti-2* 0.26
36 Radha vihar* 0.87
37 Pushapanjali vihar nala* 0.05
38 New gopal nagar-1* 0.26
39 New gopal nagar-2* 0.09
Dhamola right
40 side before Old police chowki* 0.08
confluence
41 Numaish camp* 0.5
42 Navyug Market* 0.17
43 Valmiki colony* 0.54
44 Indra camp* 0.44
45 Dhamola nadi ka pull sapna takies* 1.09
46 Indra basti-1* 0.04
49 Near Janak nagar* 0.62
50 Dhamola left side Below railway line* 0.05
51 after confluence Kapil vihar* 0.35
52 Kapil vihar near OHT* 0.17
53 Shiv bagula mukhi* 0.35
54 Brhampuri drain* 0.11
55 Gaddhe wali gali* 2.71
56 Nazirpura* 0.03
57 Taj nalla* 14.36
58 Punjabi bagh-1* 0.3
Dhamola after
59 confluence right Punjabi bagh-2* 0.2
side
60 Punjabi bagh-3* 0.9
61 Near police ground behind STP* 0.7
The concessionaire should take adequate protective measures for safe guarding existing structures/ houses
that are situated near the right of way.
A6 Operations and Maintenance for 15 years of Saharanpur Facilities i.e. Saharanpur STP and
Associated Infrastructure,
All the facilities constructed by the concessionaire, shall be maintained for 15 years after successful
commissioning of the facilities as per the detailed specifications given in Part G of the schedules to
Concession Agreement. The maintenance shall be as per the guidelines given in the CPHEEO
Manual Part B. The outlet parameters of the STP shall be within the limits laid down in Schedule
9: KPI.
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A7 Drone Based Artificial Intelligence Platform for Project Monitoring and Construction
Management
During the construction period concessionaire shall support the construction monitoring through a
suitable IT platform with following features:
• A dashboard to access real time information via Aerial Photographs(Drones), 360 degree
cameras, LIDAR scanners, IoT sensors Automatic data inputs after creating the API with the
end user Project Management Software, such as Oracle Primavera P6, Microsoft Project as
well as Excel.
• Drones, robotic cameras equipped with various sensors to map site, physical structures that
generate highly detailed 2D maps & 3D models which are highly data rich with an accuracy
level of a centimetre exterior and 5mm level accuracy on the interior of all structures and
components.
• Platform should enable NMCG/Jal Nigam to digitally measure distance, area and even volume
accurately using the high-resolution 3D Orthomosaic, Textured Mesh models etc. Further,
legacy data such as GIS data, blue prints etc. along with survey data, design data, project plans
should be integrated in the platform.
• Real time Artificial Intelligence powered insights such as as-planned vs as Built analysis, and
cost analysis thereby giving a complete picture to Jal Nigam/NMCG to identify any road blocks
or hidden issues in project execution.
• Platform also should have 3D view of the construction along with the 360-degree walkthrough
of interiors to give a clear picture of the construction progress. The platform should enable the
users to visit the site virtually from any device, and any point in time till commissioning.
• The concessionaire shall also identify suitable storage platforms/devices for storage and
retrieval of the data during the construction period. At the end of construction period the stored
data can be archived to a suitable storage device and handed over to Jal Nigam.
• Real time monitoring CCTV camera (minmum 3 nos.) shall be installed at STP site during
construction period. User rights for the same will be shared with Jal Nigam/NMCG.
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Part B - Overview of SCADA system to be employed
The schematic representation of the required RTOLMS architecture to be provided by the Concessioanire as part of Basic
engineering package to meet the KPI requirements as per schedule 1 and 10.
Typical parameter and relayed to control monitoring station for Pumping Stations Sewage Treatment Plant
Main pumping station/SPS/IPS/LS STP I&D &

Bio
commo
Description of soft Sump / Other gas
Parameters Sump / n DG set
signal Pumps collection Pumps equipm gener
collection well chambe
well ent's ation1
r
Date & Time Real time
Liquid Level High
Low
Liquid flow Inlet flow

Measurement
Sewage quality at inlet pH, TOC bases
and outlet BOD and COD,
TSS, TP, TN and
fecal coliform
Pump status for On, OFF, Trip
individual pumps
Flow rate in common Flow rate, head
header
Electrical parameter Voltage, Current,
for individual pumps KWH, PF, KVA
1
Mandatory only for Dhandhupura STP
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Main pumping station/SPS/IPS/LS STP I&D &
Bio
commo
Description of soft Sump / Other gas
Parameters Sump / n DG set
signal Pumps collection Pumps equipm gener
collection well chambe
well ent's ation1
r
& main switch board
No of operating
mechanical
equipment’s
Temperature -
Ambient, liquid
Bio gas monitoring Online status for
various activity
Gas generation Cum / day,
cumulative gas
generation, gas
quality
DG set running hours
Electrical parameter Voltage, Current,

for individual Bio gas- KWH, PF, KVA
based engine
2
generator , DG set
pumps & main switch
board
Note:
 For flow measurement at I&D, the Concessionaire is free to adopt any available flow measuring instruments with compatibility for
online monitoring
2
Including for bio gas plant
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Part C: Overview of procedural activities to be undertaken (Submissions by concessionaire with
timelines)
(a) Submit Basic Engineering Drawings as defined in the Agreement;
(b) Submit the Construction Plan for the Facilities and the Associated Infrastructure;
(c) Carry out all preparatory work like survey & investigations, clearing out debris and proper disposal
of the extra surplus excavated earth to a suitable location as per Applicable Laws;
(d) Develop the site, landscaping, arboriculture, and horticulture at the STP Site and by providing earth
filling, greenery, plantation, and diversion & extension of stormwater drainage network, etc. and
maintain condition of landscape establishment;
(e) Design and construct all necessary buildings for administrative, laboratory, PLC room buildings
for E&M equipment as per Technical Specifications, latest applicable code provisions, and good
engineering practices;
(f) Undertake electrical and instrumentation works as per Technical Specifications, latest applicable
code provisions, and good engineering practices;
(g) Provide electrical substation, as required, in accordance with the requirements of State power
corporation limited;
(h) Keep the Facilities in clean, hygienic, tidy and safe conditions;
(i) Illuminate the STP with suitable arrangement, as per the Technical Specifications;
(j) Undertake trial runs, testing, commissioning of Facilities as per the requirements of Concession
Agreement;
(k) Based on its assessment of the power supply, make necessary arrangements, as required, to ensure
continuous uninterrupted operations of the Facilities during any power supply failure from the grid;
(l) Undertake Operations and Maintenance of Facilities as per Technical Specifications and safe
disposal of Treated Effluent and STP By-Products;
(m) Develop and implement the environment, social, health and safety plans as per the requirements of
the Concession Agreement;
(n) Implement quality system and environmental management system in accordance with ISO 9001
and ISO 14001;
(o) Prepare appropriate records and reports as outlined in the Concession Agreement;
(p) Undertake security control of the Facilities
(q) Carry out the required tests and laboratory analysis;
(r) Obtain and renew licenses, permits, and certificates necessary to operate the Facilities;
(s) Hand-back the Facilities and the Associated Infrastructure to the Utter Pradesh Jal Nigam (UPJN)
at the end of the O&M Period;
Develop the necessary Design and Drawings and other submissions, as per the requirements of the
Concession Agreement. These submissions, inter-alia are outlined in the table below:
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Submissions required from the Concessionaire
Submission
Description of submission
& Timeline
Construction Detailed construction plan for the STP Facilities and the Associated Infrastructure setting
Plan before out the work plan to achieve each of the Payment Milestones, such that the STP Facilities
Effectiveness and the Associated Infrastructure are completed on or prior to the relevant Scheduled
Construction Completion Date. The construction plan should include the following
sections at the minimum:
• Site manpower and labor mobilization details. Details of project management

and health & safety personnel to be deployed at the site to be provided separately.
• Detailed implementation schedule (including details of construction milestones)
• Construction and design method statements for all activities including
survey, soil testing and all civil and electrical items.
• Details of works and equipment control
• Quality assurance plans
• Subcontracting details
Designs and Geotechnical analysis and topography survey, Geotechnical analysis report and
Drawings topography survey report
before
Effectiveness • Topographical survey reports
• Site details & topography of relevant Sites, L-sections of channels & other works
for all
• Survey records, borehole records and soil test reports
Facilities Process design and Mechanical design calculations for relevant STP Facilities and
Associated Infrastructure:
• Description of Proposed Technology including proposed treatment process,

process design calculations and mass balance diagrams
• Hydraulic calculations and Hydraulic Flow Diagram
• Details of the aeration device stating the turndown ratio
• Details of the sludge digestion system stating maintenance mechanism from
outside the digester (without draining its contents)
• Sludge handling system
• Other critical components of process designs
• Design of pumping stations being developed
• Site layout
• Location of site office, staff quarters,
• Location of batching - plant, go-down / yard, store / workshop, etc.
• Details of the storm water drainage inside the Facilities
• Layout of the embankment, if any
• Instrumentation and Control structural designs and calculations
• Process and Instrumentation Diagrams, Pipework layout diagrams including all
valves and penstocks
• Detailed L-Section drawings for all rising mains & gravity mains
• Hydraulic design calculation and profile of all rising mains & gravity mains
• ROW/ Railway/ Bridge Crossing drawings & construction methodology
• Online Monitoring
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• SCADA/instrumentation/process control system architecture
• C-ESIA for construction period
• EHS Plan for Construction Periods
• Health and Safety Standards to be applicable under project implementation
/construction
• Contractor’s Environmental and Social Management Plan as per relevant
standards and specification as applicable.
• Occupational social health and safety plan
Phase I Designs and Drawings (to be submitted for effectiveness)
Detailed construction drawings
Process design and Mechanical design calculations for relevant STP Facilities and
Associated Infrastructure:
• Design data sheets for equipment’s of all facilities being

• Pump head calculation of all facilities being developed
Site layout
• Final facilities layout: general arrangement drawings for the buildings, tanks,
foundations, Interception and Diversion works, pumping stations, process units,
approach road, Inlet Point, Outlet Point
Architectural Designs and Concepts
• Architectural work shall include walls, roof, flooring and floor finish, roof water
proofing, down water pipes, windows, ventilators, doors, glazing, equipment
access doors, painting and other ornamental works.
• Architectural statement explaining the factors considered in the design
access doors, painting and other ornamental works
Structural designs and calculations
• Detailed design calculations of foundations and superstructure

• General arrangement drawings and explanatory sketches
• Methods statement describing work procedure before commencing concrete
work
Power
• Power single line diagrams

• Process data sheets to define design criteria, installed capacities and loading rates
of principal items of plant and equipment
• Control philosophy report
• Electrical load list
Instrumentation and Control
• Instrument schedule & I/O schedule for each Motor Control Centre
• Control configuration diagram of all Facilities individually and overall
• Functional Design Specification - Comprising an overall description of the plant,
its functioning and control, and description of each section of the control system
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covering modes of operation, manual overrides, set-point and parameter
selection and adjustment. It shall describe the ‘fail-safe’ features incorporated
into the design for the event of failure of a plant item or system, or loss of an
input signal affecting a control loop or process sequence. It shall also describe
control actions taken and monitoring functions which remain available during a
power failure, and any automatic controls or sequencing which take place during
system start-up and shut-down. It shall include figures or drawings where
appropriate.
• Drawings and schedules – Including the following –
o Process and instrumentation diagram which shall comply with BS 1646
(all parts) and BS 1553-1:1977.
o General arrangement drawings of field-mounted instruments showing
installation details.
o General arrangement drawings of instrument and control panels, fully-
dimensioned in plan and elevation views, showing foundation and fixing
details, access doors, clearances, cable-entry positions, weight and
lifting arrangement.
o Layout drawings of panel fascias showing instruments, controls and
details of all labels.
o Layout drawings of panel interior showing equipment, terminal blocks
& cable ways.
o Annunciator arrangement and engraving details.
o Internal circuit and wiring diagrams for instrument and control panels.
o Schematic control diagrams.
o Instrument loop diagrams.
o Instrument wiring and piping diagrams.
o Interconnection wiring diagrams.
o Cable block diagrams, drawings and schedules.
o Instrument system and panel power distribution diagrams.
o Programmable-device functional design specifications which shall
include hardware details, logic flow charts, ladder diagrams and program
listings.
o Schedules of inputs to and outputs from programmable controllers and
telemetry outstations.
o Labeling schedules.
o Comprehensive testing schedules for all off-site, on-site, pre-
commissioning and commissioning tests and take-over tests.
o Drawings necessary for the provision of ducts, openings, trenches, fixing
holes for panels etc.
• Data and calculations
o Manufacturer’s catalogues and data sheets

o Calculations to support control system design
o Specification for protective coatings and painting
• Certificates
o Manufacturer’s works tests

o Pre-installation checks
o Pressure-testing schedules
o Instrument loop test check sheets
o Installed instrument performance tests
o System tests
15
o Statutory certificates of compliance (such as hazardous area equipment)
During Phase II Designs and Drawings (to be submitted during Construction Periods)
Construction
Periods Detailed construction drawings: design data sheets for equipment’s of all facilities being
developed Design data sheets for equipment’s of all facilities being developed
• Pump head calculation of all facilities being developed

Site LayoutSite layout
• Final facilities layout: general arrangement drawings for the buildings, tanks,
foundations, Interception and Diversion works, pumping stations, process units,
approach road, Inlet Point, Outlet Point
Architectural Designs and ConceptsArchitectural Designs and Concepts
access doors, painting and other ornamental works.
• Architectural statement explaining the factors considered in the design
access doors, painting and other ornamental works
Structural designs and calculations
• Detailed design calculations of foundations and superstructure

• General arrangement drawings and explanatory sketches
• Methods statement describing work procedure before commencing concrete
work
Power
• Power single line diagrams

• Process data sheets to define design criteria, installed capacities and loading rates
of principal items of plant and equipment
• Control philosophy report
• Electrical load list
Instrumentation and Control
Instrument schedule & I/O schedule for each Motor Control Centre nstrument
schedule & I/O schedule for each Motor Control Centre
• Control configuration diagram of all Facilities individually and overall
• Functional Design Specification - Comprising an overall description of the plant,
its functioning and control, and description of each section of the control system
covering modes of operation, manual overrides, set-point and parameter
selection and adjustment. It shall describe the ‘fail-safe’ features incorporated
into the design for the event of failure of a plant item or system, or loss of an
input signal affecting a control loop or process sequence. It shall also describe
control actions taken and monitoring functions which remain available during a
power failure, and any automatic controls or sequencing which take place during
system start-up and shut-down. It shall include figures or drawings where
appropriate.
• Drawings and schedules – Including the following –
o Process and instrumentation diagram which shall comply with BS 1646
(all parts) and BS 1553-1:1977.
16
o General arrangement drawings of field-mounted instruments showing
installation details.
o General arrangement drawings of instrument and control panels, fully-
dimensioned in plan and elevation views, showing foundation and fixing
details, access doors, clearances, cable-entry positions, weight and
lifting arrangement.
o Layout drawings of panel fascias showing instruments, controls and
details of all labels.
o Layout drawings of panel interior showing equipment, terminal blocks
& cable ways.
o Annunciator arrangement and engraving details.
o Internal circuit and wiring diagrams for instrument and control panels.
o Schematic control diagrams.
o Instrument loop diagrams.
o Instrument wiring and piping diagrams.
o Interconnection wiring diagrams.
o Cable block diagrams, drawings and schedules.
o Instrument system and panel power distribution diagrams.
o Programmable-device functional design specifications which shall
include hardware details, logic flow charts, ladder diagrams and program
listings.
o Schedules of inputs to and outputs from programmable controllers and
telemetry outstations.
o Labeling schedules.
o Comprehensive testing schedules for all off-site, on-site, pre-
commissioning and commissioning tests and take-over tests.
o Drawings necessary for the provision of ducts, openings, trenches, fixing
holes for panels etc.
• Data and calculations
o Manufacturer’s catalogues and data sheets

o Calculations to support control system design
o Specification for protective coatings and painting
• Certificates
o Manufacturer’s works tests

o Pre-installation checks
o Pressure-testing schedules
o Instrument loop test check sheets
o Installed instrument performance tests
o System tests
o Statutory certificates of compliance (such as hazardous area equipment)
Upon All as-built drawings on GIS base map of town including L- sections
Construction
Completion • Final version of the design and calculations
• Key construction records and tests
• Asset sheets
At least 90 O&M Manual separately for each component of the Facilities including the following –
days prior to
the Scheduled o O&M Procedures and activities to be performed during O&M period.
o Preventive schedule of maintenance of equipments
17
Construction o Preodic schedule of maintenance of equipments
Completion o Overall description of permits and standards, operation and control of
Date STP Facilities and Associated Infrastructure, operation and control of
sludge handling facilities, sampling and laboratory analysis, records and
reporting, maintenance, emergency O&M procedures
o Overall plan for O&M of the STP Facilities and Associated
Infrastructure with due consideration to the reliability of performance,
flexibility to cope with variability, diligence to maintain tidiness and
cleanliness, capability to respond to emergency situations and
effectiveness to handle complaints and to meet the KPIs;
o Provision of spare parts and special tools with quantity and particulars
throughout the O&M Period for effective and uninterrupted operation of
the STP Facilities and Associated Infrastructure;
o Sampling and testing methodologies to determine physical, chemical
and biological characteristics of raw Sewage and Effluent Water as per
CPHEEO manual;
o Methodology for sampling and testing of heavy metals in line with the
CPHEEO manual
o Inventory control of consumables such as fuel, sand and various types
of chemicals, dangerous goods and hazardous materials;
o Safe and proper storage and transfer of various types of materials and
chemicals, dangerous goods and hazardous materials to assure the
continuous operation of the STP Facilities and Associated Infrastructure,
the compliance with statutory requirements and avoidance of
environmental nuisance;
o Upkeep of the central control and monitoring system to ensure
availability of reliable on-line and archived data
o Arrangements for ensuring data security and integrity, and prevention of
unauthorized alteration
o Arrangements for data recovery in case of accidental loss of essential
operational data
o Arrangements for allowing flexibility of the computer database to store
and process data upon introduction of new technologies and data
management system
o Preventative maintenance and corrective maintenance requirements
o Precautionary measures and arrangements for inclement weathers
o Procedures to record and handle complaints
o Operational arrangements related to tests for KPIs
o Procedures to prepare and submit routine records and reports to the Jal
Nigam
• Operational Contingency Plan

o Identification of potential problems that may cause disruptions to
operation and assessment of potential impacts
o Measures to handle potential problems and prevent disruptions to
operation
o Measures to handle emergency situations that may cause disruptions to
operation and shutdown of the Facilities
o Precautions and procedures to resume operation after addressing of the
emergency situations; and
o Fire and emergency drill plans
18
• Human Resources Plan
o Mobilization of labor for O&M
o Means and flow of communication among field staff, staff at control
rooms and truck drivers for disposal of the Digested Sludge;
• Scheduled Maintenance Program for the first year post COD

• Emergency Procedures for:
o Fire
o Vehicle breakdown and accidents
o Facilities closure
o Procedure to handle excessive incoming Sewage due to rain, storm or
infiltration
o Floods
o Inclement weather conditions
o Unscheduled and Forced Outage
o Spillage of chemicals
o Labour disputes
• Asset Management Plan:
o Composite manual describing the functions and operations of each
equipment
o Composite manual for testing and servicing every system and individual
item
o Assets overview
 description of various components of the STP Facilities and
Associate Infrastructure
 dependencies between the components
 asset management strategy
o System performance
 design lives of plant, buildings and structures;
 benchmarks, standards and guidelines adopted for performance
tests, condition surveys and residual life assessments;
o Asset remediation plans
 schedules for overhaul and replacement of plant
 schedules for refurbishment and renewal
 planned actions to bring or keep the assets above their minimum
conditions required under the Concession Agreement
o Operational arrangements related to the survey of the Hand-back
Conditions
EHS and Occupational Health and Safety Plan:
 Waste (STP By-products, construction waste and other waste) management plan
• Sludge management plan, including a strategy and improvement measures and
actions to treat and dispose of sludge, including sludge valorization opportunities
in compliance with applicable standards
• Health and safety standards
o Hazardous material management plan
o Health and safety requirements to be followed by staff & sub-contractors
o Traffic management plan during construction
o Identification, elimination and mitigation of safety and health risks
associated with the O&M of all the Facilities;
• Environmental and social management system
o Pollution prevention plan (water, air, noise)
19
o Procedures, plans and actions to achieve compliance with the
requirements of the Concession Agreement;
o Measures to enhance and sustain the good image of the Facilities and the
Associated Infrastructure
o Plan for maintaining good communication and relationship with all
stakeholders
O&M Period Annual scheduled maintenance program every year should include preventive and
15 years periodic maintenance schedule for entire O&M period
20
Schedule 2: Format of the Substitution Agreement
[ON APPROPRIATE STAMP PAPER]
This Substitution Agreement (Substitution Agreement) is executed on this [●] day of [●] 2020
atSaharanpur:
BETWEEN
(1) UTTAR PRADESH JAL NIGAM (Rural), a statutory body constituted under the Uttar Pradesh
Water Supply and Sewerage Amendment Act, 2021, with its registered office at 6, Rana Pratap
Marg, Lucknow - 226001 (hereinafter referred to as the Jal Nigam, which expression shall, unless
it be repugnant to the context or meaning thereof, include its successors and permitted assigns);
AND
(2) NATIONAL MISSION FOR CLEAN GANGA, a statutory body constituted under the
Environment (Protection) Act, 1986, with its registered office at 1st Floor, Major Dhyanchand
National Stadium, India Gate, New Delhi - 110002 (hereinafter referred to as NMCG, which
expression shall, unless it be repugnant to the context or meaning thereof, include its successors
and permitted assigns);
AND
(3) [________________[insert name of the Concessionaire], a company organized, incorporated,

registered and existing under the Companies Act, with its registered office at
_______________________________ [insert address] acting through
_______________________________, _______________________________ [insert name of the
authorised signatory and his/her designation] duly authorized by resolution dated
_____________ [insert date of the Board Resolution] (hereinafter referred to as the
Concessionaire, which expression shall, unless it be repugnant to the context or meaning thereof,
include its successors and permitted assigns);
AND
(4) [Insertname of the Lenders' Representative] a [ ] organized/registered under the [ ], with its
registered office/head office at _______________________________ [insert address] (hereinafter
referred to as the Lenders'Representative, which expression shall, unless it be repugnant to the
context having its registered office at [insert address], acting for itself and for and on behalf of the
Lenders listed in Annexure 1.
The Jal Nigam, NMCG, the Concessionaire and the Lenders' Representative are hereinafter collectively
referred to as Parties and individually as Party.
WHEREAS:
21
A. With a view to implement the Namami Gange programme and the Ganga 2016 Order, the Jal
Nigam, in association with NMCG, has decided to undertake the Design, Build, Finance, Operate
and Transfer Sewage Treatment Plants (STPs) along with Associated Infrastructure for a period of
15 years through Hybrid Annuity Based PPP Mode in Saharanpur, Uttar Pradesh under the Namami
Gange Programme.
B. For this purpose, the Jal Nigam selected the Concessionaire post a bid process to undertake: (i) the
development of STP Facility with a proposed capacity of 135 MLD at Saharanpur, along with its
Associated Infrastructure which includes one pumping station, its rising main, nala tapping at 61
locations and appurtenant structures and allied works at Saharanpur on a PPP basis, through a
hybrid annuity model, (collectively the Project).
C. The Jal Nigam, NMCG and the Concessionaire executed a Concession Agreement dated [●] to
implement the Project (Concession Agreement).
D. The Lenders have agreed to finance the Project in accordance with the terms and conditions of the
Financing Documents and have requested the Jal Nigam and NMCG to enter into this Substitution
Agreement for securing their interests through substitution of the Concessionaire to a nominated
Company, in accordance with this Substitution Agreement.
E. The Parties have agreed to execute this Substitution Agreement on the terms and conditions
mentioned herein below.
IT IS AGREED as follows:
1. DEFINITIONS AND INTERPRETATION
1.1. Definitions
The capitalised terms used but not defined in this Agreement shall have the meaning ascribed to
them in the Concession Agreement:
Annexure means an annexure to this Substitution Agreement.
Arbitration has the meaning ascribed to it in Clause 8.2.
Article means an article of this Substitution Agreement.
Clause means a clause of this Substitution Agreement.
22
Companies Act means the (Indian) Companies Act, 1956 or the (Indian) Companies
Act, 2013, as amended from time to time, as the context may require.
Company means a company incorporated under the Companies Act or a foreign

company incorporated under the relevant statute of its jurisdiction.
Concession has the meaning ascribed to it in Recital C.

Agreement
Concessionaire means a Concessionaire Event of Default as defined under the

Event of Default Concession Agreement.
Dispute means any difference or dispute of whatsoever nature relating to this

Substitution Agreement between the Parties arising under, out of or in
connection with this Substitution Agreement.
Financial means all funded and non-funded financial assistance, including loans,
Assistance advances and guarantees or any re-financing that the Concessionaire
has availed of for the Project from the Lenders, as set out in the
Financing Documents.
Financial Default means a Concessionaire event of default as set out under the Financing
Documents.
Financing means, collectively, the documents entered into or to be entered into

Documents by the Concessionaire with the Lenders, in respect of all funded and
non-funded financial assistance, including loans, advances and or any
re-financing that the Concessionaire may avail of for the Project from
the Lenders and includes any document providing Security to the
Lenders.
Indemnified Party has the meaning ascribed to it in Clause 7.2.
Indemnifying has the meaning ascribed to it in Clause 7.2.

Party
23
Lenders means the financial institutions set out in Annexure 1.
Lenders' Dues means the aggregate of all monies owed by the Concessionaire to the
Lenders under the Financing Documents on account of principal
thereunder for funding the whole or any part of the cost to be incurred
for implementing the Project and all accrued interest, additional
interest, liquidated damages, commitment fees, commission,
prepayment premium, costs, charges and other monies including
financing charges and fees owed by the Concessionaire to the Lenders
under the Financing Documents for the Project that are payable under
the Financing Documents, up to the date of the Notice of Intent to
Terminate or notice of termination issued under the Concession
Agreement, or up to the date of issuance of the Notice of Financial
Default under the Financial Documents, as the case may be.
Notice of Dispute has the meaning ascribed to it in Clause 8.1.
Notice of Financial has the meaning ascribed to it in Clause 3.2(a).

Default
Notice of Intent to means a notice issued by the Jal Nigam upon occurrence of a
Terminate Concessionaire Event of Default in accordance with the Concession
Agreement, conveying its intention to terminate the Concession
Agreement.
Person means any individual, company, corporation, partnership, joint

venture, trust, society, sole proprietor, limited liability partnership, co-
operative society, government company, unincorporated organization
or any other legal entity.
Project has the meaning ascribed to it in Recital B.
Proposal shall have the meaning ascribed to it in Clause 4.1(c).
24
RFP means the request for proposal dated 21 November 2022 (as amended
on [●]) issued by the Jal Nigam, for conducting a bid process to
implement the Project.
Selectee means a new Company proposed by the Lenders pursuant to this

Substitution Agreement for performing the rights and obligations of
the Concessionaire for the remaining Term of the Concession
Agreement.
Substitution has the meaning ascribed to it in Clause 3.3(c).

Notice under
Concession
Agreement
Substitution has the meaning ascribed to it in Clause 3.2(b).

Notice under
Financing
Documents
1.2. Interpretation
In this Substitution Agreement, unless the context otherwise requires:
(a) Any reference to a statutory provision shall include such provision as modified or re-
enacted or consolidated from time to time.
(b) The words importing the singular shall mean the plural and vice-versa; and words
importing the masculine shall include the feminine and neuter and vice-versa.
(c) Headings in this Substitution Agreement are for convenience of reference only.
(d) The references to the word 'include' or 'including' or to the phrase 'in particular', shall be
construed without limitation.
(e) References to any date or time of day are to Indian Standard Time; any reference to day
shall mean a reference to a calendar day; any reference to a month shall mean a reference
to a calendar month, any reference to a year shall mean a reference to a calendar year.
(f) The references to any agreement or deed or other instrument shall be construed as a
reference to such agreement, deed, or other instrument as may be amended, varied,
supplemented or novated, from time to time.
25
(g) A requirement that a payment be made on a day which is not a business day shall be
construed as a requirement that the payment be made on the next business day.
(h) Whenever provision is made for the giving or issuing of any notice, endorsement, consent,
approval, permission, certificate or determination by any person, such notice, etc., shall be
reasonably given, shall not be unreasonably withheld or delayed and shall be in writing and
the words 'notify', 'endorse', 'approve', 'permit', 'certify' or 'determine' shall be construed
accordingly. Where any notice, consent or approval is to be given by either of the Parties,
the notice, consent or approval shall be given on their behalf only by any authorized
persons.
(i) The words written and in writing include a facsimile transmission and any means of
reproducing works in a tangible and permanently visible form.
(j) The provisions of the Articles, Clauses and Annexures of this Agreement shall be
interpreted in such a manner that will ensure that there is no inconsistency in interpretation
between the intent expressed in the Articles, Clauses or Annexures.
(k) In the event of any ambiguities or discrepancies between two Clauses of this Agreement,
the provisions of the specific Clause relevant to the issue under consideration shall prevail
over those in other Clauses.
(l) The rule of construction, if any, that an agreement should be interpreted against the Party
responsible for the drafting and preparation thereof shall not apply to this Agreement.
2. ASSIGNMENT
The Concessionaire hereby agrees to assign its rights, title and interest under the Concession
Agreement to and in favour of the Lenders pursuant to and in accordance with this Substitution
Agreement and the Concession Agreement by way of Security in respect of the Financial Assistance
provided by the Lenders.
The Jal Nigam and NMCG hereby consent to assignment by the Concessionaire of its rights, title
and interest under the Concession Agreement by way of Security to and in favour of the Lenders
in connection with the Financial Assistance provided by the Lenders.
3. SUBSTITUTION OF THE CONCESSIONAIRE
3.1. Right of Substitution
(a) The Jal Nigam and NMCG hereby irrevocably agree to substitute the Concessionaire with
a Selectee, selected by the Lenders in accordance with the provisions of this Substitution
Agreement and approved by the Jal Nigam.
26
(b) The Lenders shall, at their sole discretion, exercise one of the 2 modes below for
substituting the Concessionaire in accordance with the provisions set out in this Agreement
and Applicable Laws:
(i) Novation: In this case, the Concession Agreement will be novated in favour of the
Selectee, and the Selectee will be a party to the Concession Agreement; or
(ii) Share sale: In this case, the Selectee will acquire the entire Capital of the
Concessionaire, and upon such transfer, the 'Concessionaire' will be deemed to be
the Selectee under and in accordance with this Agreement.
(c) The Jal Nigam and NMCG further agree that they shall provide all necessary consents and
assistance to effect such substitution of the Concessionaire with a Selectee.
(d) It is clarified that nothing contained herein shall entitle the Lenders to design, develop,
construct, complete, operate or maintain the Facilities themselves under and in accordance
with the Concession Agreement either individually or collectively.
3.2. Procedure in case of a Financial Default
(a) Upon occurrence of a Financial Default, the Lenders' Representative shall notify the
Concessionaire by a notice, with a copy simultaneously sent to the Jal Nigam and NMCG,
about the occurrence of a Financial Default and the amount of the Lenders' Dues (Notice
of Financial Default).
The Notice of Financial Default shall be conclusive evidence of occurrence of the Financial
Default and the Lenders' Dues, and shall be final, conclusive and binding upon the
Concessionaire for the purpose of this Substitution Agreement and the Financing
Documents.
The Parties agree that the Jal Nigam shall have the right to trigger a Concessionaire Event
of Default and issue a Notice of Intent to Terminate under the Concession Agreement upon
receipt of a Notice of Financial Default.
(b) The Lenders' Representative (on behalf of the Lenders) may, after 60 days but within 90
days after the issuance of the Notice of Intent to Terminate under Clause 3.2(a) above or
such longer period as may be mutually agreed between the Jal Nigam and the Lenders,
make a representation to the Jal Nigam, stating the intention to substitute the
Concessionaire by a Selectee (Substitution Notice under Financing Documents).
In the event that the Lenders' Representative issues the Substitution Notice under Financing
Documents, then, within 90 days of issue of such notice, the Lenders shall be entitled to
undertake and complete the substitution of the Concessionaire by a Selectee, in accordance
with the provisions of this Substitution Agreement. The Lenders' right to substitute the
Concessionaire shall be without prejudice to any other right or remedy available to the
Lenders under the Financing Documents and/or this Substitution Agreement.
27
(c) If the Lenders' Representative does not convey the intention to substitute the
Concessionaire with a Selectee after 60 days but within 90 days of the Notice of Intent to
Terminate under Clause 3.2(a) above or such longer period as may be mutually agreed
between the Jal Nigam and the Lenders, or the Lenders fail to substitute the Concessionaire
within the time period set out in (b) above, the Jal Nigam shall be entitled to terminate the
Concession Agreement in accordance with its provisions.
3.3. Procedure in case of a Concessionaire Event of Default
(a) Upon occurrence of a Concessionaire Event of Default, the Jal Nigam shall issue a Notice
of Intent to Terminate to the Concessionaire
(b) If, within 60 days from the date of the Notice of Intent to Terminate, the Concessionaire
does not rectify or remedy the Event of Default to the satisfaction of the Jal Nigam or the
Jal Nigam is not satisfied with the steps taken or proposed to be taken by the Concessionaire
to remedy the Event of Default, the Jal Nigam shall issue a Notice of Intent to Terminate
to the Lenders to exercise their substitution rights.
The Notice of Intent to Terminate issued by the Jal Nigam to the Lenders under this Clause
3.3(b) shall be conclusive evidence of occurrence of the Concessionaire Event of Default,
and shall be final, conclusive and binding upon the Concessionaire for the purpose of this
Substitution Agreement and the Financing Documents.
(c) The Lenders' Representative (on behalf of the Lenders) may, after 60 days but within 90
days after the issuance of the Notice of Intent to Terminate under Clause 3.3(b) above or
such longer period as may be mutually agreed between the Jal Nigam and the Lenders
make a representation to the Jal Nigam, stating the intention to substitute the
Concessionaire by a Selectee (Substitution Notice under Concession Agreement).
In the event that the Lenders' Representative issues the Substitution Notice under
Concession Agreement, then, within 90 days of issue of such notice, the Lenders shall be
entitled to undertake and complete the substitution of the Concessionaire by a Selectee, in
accordance with the provisions of this Substitution Agreement. The Lenders' right to
substitute the Concessionaire shall be without prejudice to any other right or remedy
available to the Lenders under the Financing Documents and/or this Substitution
Agreement.
(d) If the Lenders' Representative does not convey the intention to substitute the
Concessionaire with a Selectee after 60 days but within 90 days of issuance of the Notice
of Intent to Terminateunder Clause 3.3(b) above or such longer period as may be mutually
agreed between the Jal Nigam and the Lenders, or the Lenders fail to substitute the
Concessionaire within the time period set out in (c) above, the Jal Nigam shall be entitled
to terminate the Concession Agreement in accordance with its provisions.
3.4. Criteria for Selection of Selectee
(a) The Lenders' Representative shall apply the following criteria while selecting a Company
as the Selectee:
28
(i) the Company shall meet the financial, eligibility and qualification criteria set out
in the RFP, demonstrating that it has the necessary experience and technical
qualification to construct and operate and maintain the Facilities and the
Associated Infrastructure for the remaining Term. Provided that if the Financial
Default or the Concessionaire Event of Default has occurred during the O&M
Period, the Selectee shall be required to meet only the O&M qualification criteria
set out in the RFP, in addition to the financial and eligibility criteria;
(ii) the Company shall be capable of properly discharging the duties, obligations and
liabilities of the Concessionaire under the Concession Agreement;
(iii) the Company shall provide Security to the satisfaction of the Lenders for the
repayment of Lenders' Dues;
(iv) the Company shall have the capability and shall unconditionally consent to assume
the liability for the payment and discharge of dues of the Concessionaire to the Jal
Nigam under and in accordance with the Concession Agreement and of Lenders'
Dues upon terms and conditions as agreed to with the Lenders;
(v) the Company shall have not been in breach of any agreement between itself and
NMCG, the Jal Nigam, the GoI or the GoUP; and
(vi) any other appropriate condition or criterion determined by the Lenders or the Jal
Nigam, whereby continuity in the performance of the Concessionaire's obligations
under the Concession Agreement is maintained and the Security in favour of the
Lenders under the Financing Documents is preserved.
(b) At any time prior to the approval of a Company as the Selectee by the Jal Nigam pursuant
to this Substitution Agreement, the Jal Nigam may require the Lenders' Representative to
satisfy the Jal Nigam as to the eligibility of such Selectee and the decision of the Jal Nigam
in this behalf shall be reasonable, final, conclusive and binding on the Lenders and such
Selectee.
4. MODALITIES OF SUBSTITUTION
4.1. Modalities
The following modalities shall be applicable to any substitution of the Concessionaire by the
Selectee:
(a) the Lenders' Representative may invite, negotiate, procure offers either through private
negotiations or public auction or process of tender or otherwise for the substitution of the
Concessionaire by another Company;
(b) the Lenders' Representative shall on behalf of the Lenders propose to the Jal Nigam, with
a copy to NMCG, pursuant to Clause 4.1(c), the name of such Company proposed to be the
29
Selectee for acceptance and shall apply to the Jal Nigam for grant to such Company, as
substitute to the Concessionaire, the right to design, finance, develop, construct, complete,
restore, operate, maintain and transfer the Facilities and the Associated Infrastructure under
and in accordance with and subject to and on the terms and conditions set out in the
Concession Agreement.
In case the Lenders intend to exercise their substitution rights through share transfer, the
Lenders' Representative shall also apply to the Jal Nigam for permitting such share transfer
to the Selectee upon approval in accordance with this Concession Agreement.
In case the Lenders intend to exercise their substitution rights through novation, the
Lenders' Representative shall also apply to the Jal Nigam for:
(i) novation of the Concession Agreement to such Company, upon being approved as
the Selectee, on the same terms and conditions for the remaining Term under the
Concession Agreement; and
(ii) the execution of a new substitution agreement with such Company, upon being
approved as the Selectee, for the remaining Term, on the same terms and
conditions as set out in this Substitution Agreement.
(c) the Lenders' Representative shall be entitled, within the time period set out in Clause 3.2(b)
or Clause 3.3(c) above as the case may be, to select and propose a Company as the Selectee
to the Jal Nigam (with a copy to NMCG) for its approval (Proposal). The Proposal of the
Lenders' Representative pursuant to this Clause4.1(c) shall contain the details of such
Company (including information in relation to the Company's ability to meet the technical
and financial criteria set out in the RFP), the Lenders' Dues and any other data and
information as may be relevant for the Jal Nigam to consider and take a decision on the
Proposal.
Without prejudice to the foregoing, the Lenders' Representative agrees and undertakes to
provide to the Jal Nigam (and NMCG), such further and other information and
clarifications in respect of any data, details or information, furnished by the Lenders'
Representative as the Jal Nigam and/or NMCG may reasonably require. The Jal Nigam
shall convey its approval or otherwise of such Proposal, including such Company proposed
as the Selectee, in its sole discretion within 15 days of (i) the date of receipt of the Proposal
by the Jal Nigam; or (ii) the date when the last of any further information and clarifications
in respect of any data, details or information comprised in the Proposal, have been provided
by the Lenders' Representative to the Jal Nigam, whichever is later. It is expressly agreed
between the Parties that the Proposal shall be accompanied by an unconditional
undertaking of the Company proposed as the Selectee that it shall, upon approval by the
Jal Nigam of the Proposal, perform and fulfill the terms and conditions of the Concession
Agreement as if such Company was the original signatory to the Concession Agreement
and shall be liable for and shall assume, discharge and pay the Lenders' Dues under and in
accordance with the terms and conditions of the Financing Documents. Upon approval of
the Proposal by the Jal Nigam, the Company shall become the Selectee hereunder;
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(d) the Jal Nigam shall, upon its satisfaction of the eligibility of the Selectee and in accordance
with the provisions of this Substitution Agreement and subject to the provisions of Clause
4.1(e), proceed to substitute the Concessionaire with the Selectee by novation of the
Concession Agreement or such other form of document as the Jal Nigam and NMCG may
reasonably require, on the same terms and conditions as set out under the Concession
Agreement for the remaining Term; or (ii) by requiring the Selectee to acquire the entire
Capital of the Concessionaire, in accordance with Applicable Laws;
(e) the substitution as aforesaid shall be subject to the Selectee completing corporate
compliances for executing the documents and obtaining Applicable Permits necessary for
implementing and/or operating and maintaining the Facilities and the Associated
Infrastructure under and in accordance with the Concession Agreement;
(f) the Jal Nigam shall have the right to object to the choice of the proposed Selectee after
hearing the Lenders' Representative, provided however, that in the event of a refusal as
stated above, the Lenders' Representative may propose another Company as the Selectee,
within 90 days of the issuance of the Substitution Notice under Financing Documents or
Substitution Notice under Concession Agreement, as the case may be. In the event that no
objection is raised with respect to the Company proposed to be the Selectee by the Jal
Nigam within the period set forth in Clause 4.1(c), the Company proposed as the Selectee
shall be deemed to have been accepted by the Jal Nigam;
(g) the substitution as aforesaid, shall be deemed to be complete only upon the Selectee
accepting and complying with the terms and conditions stipulated in the Concession
Agreement; and
(h) all actions of the Lenders' Representative hereunder shall be deemed to be on behalf of the
Lenders and be binding upon them.
4.2. Waiver of Concessionaire's Right to Remedy
The Concessionaire hereby irrevocably agrees and waives any right to challenge the Lenders'
decision to apply to the Jal Nigam for substitution as aforesaid and neither the Concessionaire nor
the Jal Nigam shall be entitled to prevent the Lenders' Representative from proceeding to seek such
a substitution of the Concessionaire by the Selectee as provided in this Article 4. The Parties
acknowledge that the rights of the Lenders under this Article 4 are irrevocable and shall not be
contested in any proceedings before any court of law and the Concessionaire shall not have any
right or remedy to prevent, obstruct, injunct or restrain the Jal Nigam and/or the Lenders from
effecting or causing the substitution as aforesaid. No third party shall have the right to question the
decision of the Lenders/Lenders' Representative, the Jal Nigam or NMCG in relation to substitution
of the Concessionaire.
4.3. No Guarantee
Nothing contained in this Article 4 shall mean or be interpreted as provision of any guarantee or
surety by the Jal Nigam or NMCG and it is expressly agreed that the Jal Nigam and NMCG have
31
not provided any surety, guarantee or counter guarantee whether directly or indirectly for the
recovery of amount of Financial Assistance advanced by the Lenders to the Concessionaire.
5. INTERIM PROTECTION
If the Lenders notify the Jal Nigam of a Financial Default and until such time that a Selectee is
approved in accordance with this Substitution Agreement, the Lenders agree that the Jal Nigam
shall (either itself or through an entity nominated by it) be entitled to maintain, preserve and protect
the Facilities and the Associated Infrastructure if, in the Jal Nigam's opinion, it is necessary and
required for the construction or operation and maintenance of the Facilities and the Associated
Infrastructure. In case of such interim protection during the O&M Period, the Jal Nigam or an entity
nominated by the Jal Nigam shall operate and maintain the Facilities and the Associated
Infrastructure pending the substitution of the Concessionaire by the Selectee.
6. STAND-STILL
The Jal Nigam agrees that on the occurrence of any Concessionaire Event of Default or a Financial
Default, it shall not exercise: (a) its right to step-in in place of the Concessionaire; (b) suspend or
terminate the Concession Agreement; or (c) take any action for the winding-up of the
Concessionaire or the appointment of a receiver or administrator in respect of the Concessionaire's
business and assets, until expiry of the time period available to the Lenders to exercise the
substitution rights, as set out in Article 3.
7. INDEMNITY
7.1 Indemnity
(a) The Concessionaire shall indemnify, defend and hold harmless the Jal Nigam, NMCG, the
Lenders and the Lenders' Representative against any and all proceedings, actions and third
party claims for any loss, damage, cost and expenses of whatever kind and nature arising
out of any breach by the Concessionaire of any of its obligations under this Substitution
Agreement or on account of failure of the Concessionaire to comply with Applicable Laws
and Applicable Permits.
(b) The Lender shall indemnify, defend and hold harmless the Jal Nigam and NMCG against
any and all proceedings, actions and third party claims for any loss, damage, cost and
expenses arising out of the Lenders' or the Lenders' Representative's failure to fulfill their
obligations under this Substitution Agreement, materially or adversely affecting the
performance of the Concessionaire's, the Jal Nigam's or NMCG's obligations under the
Concession Agreement, other than any loss, damage, cost and expenses arising out of acts
done in discharge of their lawful functions by the Lenders/Lenders' Representative.
7.2 Notices and Contest of Claims
In the event that any Party receives a claim from a third party in respect of which it is entitled to
the benefit of an indemnity under Clause 7.1 or in respect of which it is entitled to reimbursement
(Indemnified Party), it shall notify the other Party responsible for indemnifying such claim
32
hereunder (Indemnifying Party) within 30 days of receipt of claim and shall not settle or pay the
claim without prior approval of the Indemnifying Party, such approval not being unreasonably
withheld or delayed. In the event that the Indemnifying Party wishes to contest or dispute the claim,
it may conduct the proceedings in the name of the Indemnified Party and shall bear all costs
involved in contesting it. The Indemnified Party shall provide all cooperation and assistance in
contesting any claim and shall sign all such writings and documents as the Indemnified Party may
reasonably require.
8. DISPUTE RESOLUTION
8.1 Amicable Settlement
In the event of a Dispute, either Party may give the other written notice at any time of a Dispute
having arisen (Notice of Dispute). The Notice of Dispute shall set out brief details of the nature of
the Dispute.
The Parties agree that they shall endeavor to resolve any Dispute amicably and in good faith within
30 days of a Notice of Dispute being served by one Party on the other Party in respect of that
Dispute. In the event that resolution of the Dispute is reached pursuant to this Clause 8.1, the
resolution and its terms shall be recorded in writing and signed by one representative from each of
the Parties.
8.2 Dispute Resolution by Arbitration
Failing amicable settlement and/or settlement of a Dispute pursuant to the provisions of Clause 8.1,
each of the Parties unconditionally and irrevocably agrees to the submission of such Dispute to
binding arbitration governed by the Arbitration and Conciliation Act, 1996.
Any arbitration proceedings commenced pursuant to this Clause 8.2 shall be referred to as the
Arbitration.
If a Dispute is referred to Arbitration by any Party, such Dispute shall be resolved by a sole
arbitrator to be appointed by mutual agreement of the Parties. If Parties fail to appoint an arbitrator
within 30 days after service of the notice of Arbitration, such arbitrator shall be appointed in
accordance with the provisions of the Arbitration Act.
8.3 Place of Arbitration
The place of the Arbitration shall be New Delhi.
8.4 English Language
The request for the Arbitration, the answer to the request, the terms of reference, any written
submissions, any orders and rulings pursuant to the Arbitration shall be in English and, if oral
hearings take place, English shall be the language to be used in the hearings.
8.5 Fees and Expenses
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The fees and expenses of the arbitrator and all other expenses of the Arbitration shall be initially
borne and paid by respective Parties, subject to determination by the arbitrator. The arbitrator may
provide in the award for the reimbursement to the prevailing Party of its costs and expenses in
bringing or defending the Arbitration claim, including legal fees and expenses incurred by such
Party.
8.6 Performance of Obligations during the Pendency of the Arbitration Proceedings
The Substitution Agreement and rights and obligations of the Parties shall remain in full force and
effect pending the award under any Arbitration proceedings pursuant to this Article 8.
8.7 Survival
The provisions of this Article 8 shall survive the termination of the Substitution Agreement.
9. GOVERNING LAW AND JURISDICTION
The Substitution Agreement shall be construed and interpreted in accordance with and governed
by the laws of India, and the courts in Saharanpur shall have exclusive jurisdiction over matters
arising out of or relating to this Substitution Agreement.
10. MISCELLANEOUS
10.1 Duration of this Agreement
This Agreement shall come into force from the date hereof and shall expire at the earliest to occur
of the following events:
(a) termination of the Concession Agreement; or
(b) no sum remains to be advanced and no sum are outstanding to the Lenders, under the
Financing Documents.
10.2 Survival
(a) Any cause or action which may have occurred in favor of any Party or any right which is
vested in any Party under this Agreement as a result of any act, omission, deed, matter or
thing done or omitted to be done by any Party before the expiry of the Term by efflux of
time or otherwise in accordance with this Agreement, shall survive the expiry of the
Agreement.
(b) The provisions of this Agreement, to the fullest extent necessary to give effect thereto,
survive the Term or the termination of this Agreement and the obligations of Parties to
be performed or discharged following the termination of this Agreement, shall
accordingly be performed or discharged by the Parties.
34
10.3 Counterparts
This Agreement may be executed in four counterparts, each of which, when executed and delivered,
will be an original, and all four counterparts together shall constitute one and the same instrument.
10.4 Waivers and Consents
(a) Unless otherwise specified, any provision or breach of any provision of this Agreement
may be waived before or after it occurs only if evidenced by an agreement in writing
signed by the Parties.
(b) Any consent under or pursuant to any provision of this Agreement must also be in writing
and given prior to the event, action or omission for which it is sought.
(c) Any such waiver or consent may be given subject to any conditions thought fit by the
Party giving it and shall be effective only in the instance and for the purpose for which it
is given.
10.5 Severability
(a) If any provision of this Agreement is or becomes illegal, invalid or unenforceable in any
respect under any Applicable Law, the legality, validity or enforceability of the remaining
provisions will not, in any way, be affected or impaired.
(b) The Parties shall negotiate in good faith with a view to agreeing one or more provisions
which may be substituted for any such invalid, illegal or unenforceable provision and
which produce as nearly as is practicable in all the circumstances the appropriate balance
of the commercial interests of the Parties.
10.6 Waiver of sovereign immunity
The Jal Nigam and NMCG unconditionally and irrevocably:
(a) agree that the execution, delivery and performance by it of this Agreement constitute
commercial acts done and performed for commercial purpose;
(b) agree that, should any proceedings be brought against it or its assets, property or revenues
in any jurisdiction in relation to this Agreement or any transaction contemplated by this
Agreement, no immunity (whether by reason of sovereignty or otherwise) from such
proceedings shall be claimed by or on behalf of the Jal Nigam and NMCG with respect to
its assets; and
(c) consent to the enforcement of any judgment or award against them in any such proceedings.
10.7 Language
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(a) The formal text of this Agreement and other agreements in relation to the Project shall be
in the English language.
(b) All notices and communications between the Parties under this Agreement shall be in
English.
10.8 Third Parties
This Agreement and all rights hereunder are intended for the sole benefit of the Parties, and shall
not imply or create any rights on the part of, or obligations to, any other Person.
10.9 Representations and Warranties
The Parties hereto expressly represent and warrant that they are duly empowered to sign and
execute this Substitution Agreement.
10.10 Notices
Notices under this Substitution Agreement shall be sent to the addresses first hereinabove
mentioned and Annexure 1 (in case of Lenders). Any change in the address of any Party shall be
duly notified by registered post acknowledgement due and delivered to other Parties.
10.11 Amendments to Substitution Agreement
(a) This Substitution Agreement shall not be affected by re-organization of any Lender,
Lenders' Representative, the Jal Nigam or NMCG and the successor-in-interest of such
Lender, Lenders' Representative, the Jal Nigam or NMCG shall have the benefit of this
Substitution Agreement.
(b) No amendment, variation or modification to this Substitution Agreement shall be valid and
effectual unless made in writing and executed by the duly authorized representatives of all
the Parties.
(c) All stamp duties or other imposts and charges as are applicable on this Substitution
Agreement or on novation of the Concession Agreement for the purpose of substitution as
specified in this Substitution Agreement shall be borne by the Concessionaire. In the event
of Lenders making such payment in the interim, such amount shall be deemed to be a part
of the Lenders' Dues.
10.12 Harmonious Construction
(a) For the purpose of giving full and proper effect to this Substitution Agreement, the
Concession Agreement and this Substitution Agreement shall be read together and
construed harmoniously. The terms of the Concession Agreement shall prevail in the event
of any inconsistencies with this Substitution Concession Agreement.
(b) The consultation, recommendation or approval of the Lenders' Representative under this
Substitution Agreement shall always be taken as consultation, recommendation or approval
36
of every concerned Lender and each such Lender shall be bound by the same and hereby
waives its right to question or dispute it.
(c) This Substitution Agreement shall be in addition to and shall not be in derogation of the
terms of the Financing Documents.
(d) It shall not be necessary for the Lenders or the Lenders' Representative to enforce or
exhaust any other remedy available to them before invoking the provisions of this
Substitution Agreement.
In witness whereof the Parties hereto have signed this Agreement on this ____________day of
____________2022.
UTTAR PRADESH JAL NIGAM

By: Superintending Engineer, UP Jal Nigam (Rural)
Saharanpur Construction Unit
Name: Mr.
Title: Superintending Engineer
NATIONAL MISSION FOR CLEAN GANGA

By:
Name:
Title:
[CONCESSIONAIRE]
By:
Name:
Title:
[LENDERS'REPRESENTATIVE]
By:
Name:
Title:
37
ANNEXURE 1
S.No. Details of Lenders
1. [_____________________[insert name of the Lender]], registered under the [], with

its registered office at [___________________________________________ [insert
address]] and branch office at [___________________________________________
[insert address]]
2. [_____________________[insert name of the Lender]], registered under the [] , with

its registered office at [___________________________________________ [insert
address]] and branch office at [___________________________________________
[insert address]]
38
Schedule 3: Format of the Escrow Agreement
(ON APPROPRIATE STAMP PAPER)
THIS ESCROW AGREEMENT (this Escrow Agreement) is entered into at [ ] on [ ] by and among:
(5) UTTAR PRADESH JAL NIGAM (Rural), a statutory body constituted under the Uttar Pradesh
Water Supply and Sewerage Amendment Act, 2021, with its registered office at 6, Rana Pratap
Marg, Lucknow - 226001 (hereinafter referred to as the Jal Nigam, which expression shall, unless
it be repugnant to the context or meaning thereof, include its successors and permitted assigns);
AND
(6) NATIONAL MISSION FOR CLEAN GANGA, a statutory body constituted under the
Environment (Protection) Act, 1986, with its registered office at 1st Floor, Major Dhyanchand
National Stadium, India Gate, New Delhi - 110002 (hereinafter referred to as NMCG, which
expression shall, unless it be repugnant to the context or meaning thereof, include its successors
and permitted assigns);
AND
(7) [________________[insert name of the Concessionaire], a company organized, incorporated,

registered and existing under the Companies Act, with its registered office at
_______________________________ [insert address] acting through
_______________________________, _______________________________ [insert name of the
authorised signatory and his/her designation], duly authorized by resolution dated
_____________ [insert date of the Board Resolution] (hereinafter referred to as the
Concessionaire, which expression shall, unless it be repugnant to the context or meaning thereof,
include its successors and permitted assigns).
AND
(8) [Insert name of Escrow Bank], a bank duly constituted in accordance with Applicable Laws and
carrying on the business of banking in India as a Scheduled Commercial Bank, with its registered
office at [insert address] and acting for the purposes of this Escrow Agreement through its branch
office at [insert address] (hereinafter referred to as Escrow Bank, which expression shall unless
repugnant to the context or meaning thereof includes its successors and permitted assigns).
The Jal Nigam, NMCG, the Concessionaire and the Escrow Bank are collectively referred to as Parties and
individually as Party.
WHEREAS:
A. With a view to implementing the Namami Gange programme and the Ganga 2016 Order, the Jal
Nigam, in association with NMCG, has decided to undertake the development and operation of
Design, Build, Rehabilitate, Finance, Operate and Transfer Sewage Treatment Plants (STPs) along
39
with Associated Infrastructure for a period of 15 years under the Hybrid Annuity Based PPP Mode
in Saharanpur, Uttar Pradesh, under the Namami Gange Programme.
B. For this purpose, the Jal Nigam selected the Concessionaire post a bid process to undertake: (i) the
development of one STP Facility with a proposed capacity of 135 MLD at Saharanpur, along with
its Associated Infrastructure which includes one pumping station, its rising main, nala tapping at
61 locations and appurtenant structures and allied works at Saharanpur on a PPP basis, through a
hybrid annuity model, (collectively the Project).
C. The Jal Nigam, NMCG and the Concessionaire executed a Concession Agreement dated [ ] to
implement the Project (Concession Agreement), which is annexed to this Escrow Agreement.
D. In consideration of the Concessionaire designing, developing, financing, constructing, completing,

operating and maintaining the Facilities on the Site for the Term, NMCG is required to pay the
Concessionaire: (i) during the relevant Construction Period, the relevant Construction Payments
upon satisfactory completion of works corresponding to Payment Milestones; and (ii) during the
O&M Period, the relevant O&M Payments comprising the Capex Annuity (along with interest),
the O&M Charges and the Power Charges for the Facilities at actuals (subject to the cap on the
Power Charges based on the Guaranteed Energy Consumption).
E. As per the provisions of the Concession Agreement, NMCG, the Jal Nigam, and the Concessionaire
are required to enter into an escrow agreement with an escrow bank and NMCG is required to open
an escrow account with such escrow bank and maintain the Minimum Escrow Balance for the
payment of the Construction Payments and the O&M Payments.
F. The escrow account shall be funded by NMCG in accordance with the terms of this Escrow
Agreement and such account shall serve to secure NMCG's payment obligations towards the
Concessionaire under the Concession Agreement.
G. The Escrow Bank is willing to serve as an escrow bank in accordance with the terms and conditions
of this Escrow Agreement.
NOW, THEREFORE, the Parties hereto agree as follows:
1. DEFINITIONS AND INTERPRETATION
1.1 Capitalized terms used but not defined in this Escrow Agreement shall have the meaning given to
them in the Concession Agreement.
1.2 In this Escrow Agreement, unless the context otherwise requires:
(a) Any reference to a statutory provision shall include such provision as modified or reenacted
or consolidated from time to time.
(b) The words importing the singular shall mean the plural and vice-versa; and words
importing the masculine shall include the feminine and neuter and vice-versa.
40
(c) Headings in this Escrow Agreement are for convenience of reference only.
(d) The references to the word 'include' or 'including' or to the phrase 'in particular', shall be
construed without limitation.
(e) References to any date or time of day are to Indian Standard Time; any reference to day
shall mean a reference to a calendar day; any reference to a month shall mean a reference
to a calendar month, any reference to a year shall mean a reference to a calendar year.
(f) The references to any agreement or deed or other instrument shall be construed as a
reference to such agreement, deed, or other instrument as may be amended, varied,
supplemented or novated, from time to time.
(g) Whenever provision is made for the giving or issuing of any notice, endorsement, consent,
approval, permission, certificate or determination by any person, such notice, etc., shall be
reasonably given, shall not be unreasonably withheld or delayed and shall be in writing.
Where any notice, consent or approval is to be given by either of the Parties, the notice,
consent or approval shall be given on their behalf only by any authorized persons.
(h) The words written and in writing include a facsimile transmission and any means of
reproducing works in a tangible and permanently visible form.
(i) The provisions of the clauses of this Escrow Agreement shall be interpreted in such a
manner that will ensure that there is no inconsistency in interpretation between the intent
expressed in the clauses.
(j) In the event of any ambiguities or discrepancies between two clauses of this Escrow
Agreement, the provisions of the specific clause relevant to the issue under consideration
shall prevail over those in other clauses.
(k) The rule of construction, if any, that an agreement should be interpreted against the Party
responsible for the drafting and preparation thereof shall not apply to this Escrow
Agreement.
2. ESCROW ACCOUNT
2.1 Appointment
(a) NMCG, the Jal Nigam and the Concessionaire hereby appoint the Escrow Bank to serve as
the escrow bank for the purposes of this Escrow Agreement and the Escrow Bank hereby
accepts this appointment.
(b) NMCG hereby settles in trust with the Escrow Bank a sum of INR 1,000 (Rupees one
thousand). The Escrow Bank has accepted the above amount of INR 1,000 (Rupees one
thousand) in trust declared and, subject to the terms and conditions in this Escrow
Agreement, agreed to act as trustee for the benefit of the Concessionaire, NMCG and the
Jal Nigam.
41
(c) The Escrow Bank shall hold and safeguard the Escrow Account and any monies held
therein, during the term of this Escrow Agreement and shall treat the amount in the Escrow
Account as monies deposited by NMCG with the Escrow Bank in trust in accordance with
the provisions of this Escrow Agreement. In performing its functions and duties under this
Escrow Agreement, the Escrow Bank shall act as an agent of NMCG, the Jal Nigam and
the Concessionaire.
2.2 Escrow Account
(a) NMCG has established a bank account in the name of [●] (name of account and account
number), with [●] (name of the bank), which shall be an interest bearing, no lien account,
denominated in Indian Rupees for the benefit of the Concessionaire (the Escrow Account).
(b) The Escrow Bank shall provide details of the Escrow Account in writing to the
Concessionaire and the Jal Nigam, including the date of opening of the Escrow Account.
(c) The Parties agree and acknowledge that:
(i) the Escrow Account shall be opened pursuant to, and specifically for the purposes
of, this Escrow Agreement and shall be used and operated only for the purposes
and in the manner provided in this Escrow Agreement and for no other use or
purposes and in no other manner;
(ii) the Escrow Bank shall maintain the Escrow Account in accordance with the terms
of this Escrow Agreement and its usual practices and applicable regulations;
(iii) the Escrow Bank and the Concessionaire, after consultation with NMCG, shall
agree on the detailed mandates, terms and conditions and operating procedures for
the Escrow Account, but in the event of any inconsistency between this Escrow
Agreement and such mandates, the terms and conditions or procedures in this
Escrow Agreement shall prevail; and
(iv) no instruction shall be given to the Escrow Bank which is not contemplated by or
which is contrary to or inconsistent with this Escrow Agreement. In the event any
such inconsistent or contrary instruction is given, the same shall be null and void
and the Escrow Bank shall not be obliged to act upon, and shall ignore, such
instructions and continue to comply with the provisions of this Escrow Agreement.
2.3 Deposits into Escrow Account
(a) Construction Period Minimum Escrow Balance

i. Construction Period Minimum Escrow Balance: NMCG shall deposit an amount
equivalent to the first Payment Milestone prior to the Effective Date. From the
Effective Date, NMCG shall ensure that the Escrow Account is funded with an amount
equivalent to the next Payment Milestone until the Saharanpur Facilities COD,
whichever is later (the Construction Period Minimum Escrow Balance); and
42
ii. O&M Period Minimum Escrow Balance: On and from the Saharanpur Facilities COD,
whichever is earlier, and until the End of the Concession, NMCG shall deposit into the
Escrow Account, by an agreed date towards the beginning of each calendar quarter, an
amount equivalent to the O&M Payments owed to the Concessionaire for the
Saharanpur Facilities for such quarter (O&M Period Minimum Escrow Balance)
(b) NMCG shall ensure that the minimum balance in the Escrow Account at all times during the
Construction Period and O&M Period is not less than the Construction Period Minimum
Escrow Balance and O&M Period Minimum Escrow Balance.
If at any time during the Construction Period or the O&M Period, the balance in the Escrow
Account falls below the Construction Period Minimum Escrow Balance or the O&M Period
Minimum Escrow Balance respectively, NMCG shall promptly, and in any event, no later
than 90 days after such occurrence, fund the Escrow Account such that the Construction
Period Minimum Escrow Balance or the O&M Period Minimum Escrow Balance is
maintained.
(c) The Parties agree that a failure to maintain the Construction Period Minimum Escrow Balance
for 90 days and the O&M Period Minimum Escrow Balance for 180 days will be treated as an
NMCG Event of Default and, in such case, the consequences set out in the Concession
Agreement shall apply.
(d) Any interest earned on the amounts deposited by NMCG in the Escrow Account will be
counted towards the Construction Period Minimum Escrow Balance or the O&M Period
Minimum Escrow Balance, as the case may be.
2.4 Withdrawals from Escrow Account during the Construction Period
(a) Upon successful completion and verification of a Payment Milestone as per the Concession
Agreement, the Jal Nigam is required to approve the Invoice raised by the Concessionaire
within 10 days of receipt of the Invoice and issue a Payment Certificate to the Escrow Bank.
The Payment Certificate shall convey the Jal Nigam's approval for the release of the amount
specified in the Invoice for the relevant Payment Milestone, less any necessary deductions
or adjustments in accordance with the Concession Agreement and/or Applicable Laws
(including for payments to be made by the Concessionaire under applicable labour laws).
(b) If, within 10 days from the date of receipt of an Invoice, the Jal Nigam does not dispute an
Invoice, the Invoice shall be deemed to have been accepted by the Jal Nigam, and the
Concessionaire shall have the right to issue instructions to the Escrow Bank (with a copy
to the Jal Nigam and NMCG) to release the amounts specified in the Invoice, upon the
expiry of the 10-day period. Any such instruction issued by the Concessionaire to the
Escrow Bank shall be accompanied by the Invoice raised by the Concessionaire for the
relevant Payment Milestone.
(c) Immediately upon receipt of a Payment Certificate from the Jal Nigam in accordance with
Clause 2.4(a) above or upon receipt of instructions from the Concessionaire in accordance
with Clause 2.4(b) above, the Escrow Bank shall release the amount specified in the
43
Payment Certificate or, if no Payment Certificate has been issued, the amount specified in
the relevant Invoice, to the bank account of the Concessionaire mentioned below:
Bank:
Account number:
BIC (SWIFT):
Address of Bank:
[Insert bank account details]
The Concessionaire may change the above bank account details by giving a 5-day prior
written notice to the Escrow Bank, NMCG and the Jal Nigam.
(d) Upon any termination of the Concession Agreement during the Construction Period of
STPs and Associated Infrastructure in Saharanpur, NMCG shall issue instructions to the
Escrow Bank requesting it to release and transfer any amounts due and payable to the
Concessionaire, including termination payments, if any, as certified by NMCG in a
statement, and any remaining amounts standing to the credit of the Escrow Account shall
be transferred to the following account of NMCG:
Bank:
Account number:
BIC (SWIFT):
Address of Bank:
NMCG may change the above bank account details by giving 5-day prior written notice to
the Escrow Bank, the Concessionaire and the Jal Nigam.
2.5 Withdrawals from Escrow Account during the O&M Period
(a) For O&M Payments in each quarter, the Jal Nigam is required to approve the Invoice raised
by the Concessionaire within 10 days of receipt of the Invoice and issue a Payment
Certificate to the Escrow Bank. The Payment Certificate shall convey the Jal Nigam's
approval for the release of the amount specified in the Invoice, less any necessary
deductions or adjustments in accordance with the Concession Agreement and/or Applicable
Laws (including for payments to be made by the Concessionaire under applicable labour
laws).
(b) If, within 10 days from the date of receipt of an Invoice, the Jal Nigam does not dispute an
Invoice, the Invoice shall be deemed to have been accepted by the Jal Nigam, and the
Concessionaire shall have the right to issue instructions to the Escrow Bank (with a copy
to the Jal Nigam and NMCG) to release the amounts specified in the Invoice, upon the
expiry of the 10-day period. Any such instruction issued by the Concessionaire to the
Escrow Bank shall be accompanied by the Invoice raised by the Concessionaire.
44
(c) Immediately upon receipt of a Payment Certificate from the Jal Nigam in accordance with
Clause 2.5(a) above or upon receipt of instructions from the Concessionaire in accordance
with Clause 2.5(b) above, the Escrow Bank shall release the amount specified in the
Payment Certificate or, if no Payment Certificate has been issued, then the amount specified
in the relevant Invoice, to the bank account of the Concessionaire mentioned below:
Bank:
Account number:
BIC (SWIFT):
Address of Bank:
The Concessionaire may change the above bank account details by giving a 5-day prior
written notice to the Escrow Bank, NMCG and the Jal Nigam.
(d) In the event the balance in the Escrow Account is insufficient to meet a quarterly payment
owed by NMCG to the Concessionaire during the O&M Period as of the due date of such
payment, the Escrow Bank may draw on a letter of credit (L/C) to be procured by NMCG
and guaranteed by IBRD, such draw to be made in accordance with the provisions of the
agreement to be concluded between the L/C-issuing bank and the Escrow Bank in relation
to the L/C.
(e) Upon any termination of the Concession Agreement during the O&M Period, NMCG shall
issue instructions to the Escrow Bank requesting it to release and transfer any amounts due
and payable to the Concessionaire, including termination payments, if any, as certified by
NMCG in a statement, and any remaining amounts standing to the credit of the Escrow
Account shall be transferred to the following account of NMCG:
Bank:
Account number:
BIC (SWIFT):
Address of Bank:
NMCG may change the above bank account details by giving 5-day prior written notice to the
Escrow Bank, the Concessionaire and the Jal Nigam.
2.6 Identification and Separation
The Escrow Bank shall clearly identify in its records the Escrow Account as an escrow account and
shall keep the funds standing to the credit of the Escrow Account separated and segregated from
the Escrow Bank's own funds or the funds of any of its other customers or third parties.
2.7 Fees
45
NMCG shall pay [Rs. NIL per annum] as fees to the Escrow Bank for the establishment and
management of the Escrow Account. NMCG shall pay such fees to the Escrow Bank within 10
days of receipt of an invoice from the Escrow Bank.
2.8 Escrow Account Statements
The Escrow Bank shall provide monthly statements regarding the Escrow Account to NMCG, the
Jal Nigam and the Concessionaire.
3. ESCROW AMOUNT
3.1 Promptly upon NMCG transferring any amount to the Escrow Account, the Escrow Bank shall send
a notice to the Concessionaire and the Jal Nigam notice informing them of the transfer.
3.2 The Escrow Bank shall hold all amounts in the Escrow for the sole benefit of the Concessionaire.
Subject to Clauses 2.4(d) and 2.5(d) of this Escrow Agreement, the Escrow Bank shall not release
any amount in the Escrow Account to any person other than the Concessionaire.
3.3 The Escrow Bank shall not apply any right of set-off against the amount in the Escrow Account,
grant any lien over such amount, or apply any fee or deduction in relation to such amount.
4. RIGHTS, DUTIES AND OBLIGATIONS OF THE ESCROW BANK
4.1 The Escrow Bank:
i. may, in the absence of bad faith, fraud, wilful default or gross negligence on its part, rely as to
any matters of fact which might reasonably be expected to be within the knowledge of NMCG
or the Jal Nigam, as the case may be, upon a certificate signed by or on behalf of NMCG or the
Jal Nigam, as the case may be;
ii. may, in the absence of bad faith, fraud, wilful default or gross negligence on its part, rely upon
the authenticity of any communication or documents believed by it to be authentic;
iii. shall, within 5 days after receipt, deliver a copy to the Jal Nigam and NMCG of any notice or
document received by the Escrow Bank from the Concessionaire or any other Person hereunder
or in connection herewith;
iv. shall, within 5 days after receipt, deliver a copy to the Concessionaire of any notice or document
received by the Escrow Bank from the Jal Nigam or NMCG in connection herewith;
v. shall maintain all records of deposits and withdrawals from the Escrow Account for the term
of this Escrow Agreement; and
46
vi. shall, not later than the [tenth (10th)] day after the beginning of each quarter during the O&M
Period, notify IBRD in writing of (A) the available balance in the Escrow Account, and (B) the
amount of any shortfall in the event that such balance is insufficient to meet the upcoming
quarterly O&M Payment due to the Concessionaire.
4.2 The duties of the Escrow Bank are only as herein specifically provided and are purely
administrative in nature. The Escrow Bank shall neither be liable for, nor chargeable with
knowledge of, the terms and conditions of any other agreement, instrument or document in
connection herewith, including, without limitation, the Concession Agreement, and shall be
required to act in respect of the amounts in the Escrow Account only as provided in this Escrow
Agreement. This Escrow Agreement sets out all the obligations of the Escrow Bank with respect to
any and all matters pertinent to the Escrow Account contemplated hereunder and no additional
obligations of the Escrow Bank shall be implied from the terms of any other agreement. The Escrow
Bank shall incur no liability in connection with the discharge of its obligations under this Escrow
Agreement or in connection therewith, except such liability as may arise from the Escrow Bank's
negligence, wilful misconduct or otherwise from any breach of this Escrow Agreement. Such
liability, however, shall not exceed the amount in the Escrow Account at the date of the said breach
by the Escrow Bank.
4.3 The Escrow Bank shall not be required to perform any acts which will violate any Applicable Laws.
4.4 In the event of any bankruptcy proceedings or enforcement proceedings against any of the Parties
pursuant to Applicable Laws, the Escrow Bank shall, notwithstanding the provisions of this Escrow
Agreement, act and perform in accordance with Applicable Laws.
5. ESCROW AGREEMENT DEFAULTS
5.1 Any breach by the Concessionaire of the terms of this Escrow Agreement, which breach the
Concessionaire fails to remedy within 5 days to the satisfaction of the Jal Nigam and NMCG, shall
be treated as an Escrow Default, unless such breach has occurred as a result of any act or omission
of NMCG or the Jal Nigam.
5.2 The Parties agree that an Escrow Default in terms of this Escrow Agreement shall be treated as a
Concessionaire Event of Default under the Concession Agreement, and the consequences of an
Escrow Default shall be dealt with in accordance with the Concession Agreement.
5.3 Upon the occurrence of an Escrow Default, the Concessionaire agrees that NMCG shall have the
right to direct the Escrow Bank to suspend withdrawals from the Escrow Account until further
notice from NMCG.
6. MISCELLANEOUS
6.1 Representations and Warranties
Each Party represents and warrants that:
(a) it has the authority to enter into this Escrow Agreement;
47
(b) this Escrow Agreement constitutes a legally valid and binding obligation, enforceable against
it in accordance with its terms;
(c) its entry into and/or performance under this Escrow Agreement is not in breach of any express
or implied terms of any contract with or other obligation to any third party; and
(d) it is solvent and able to perform all of its obligations under this Escrow Agreement.
6.2 Notices
Any notice or other communication to be given or made under this Escrow Agreement to the Parties
shall be in writing. Except as otherwise provided in this Escrow Agreement, such notice, request
or other communication shall be delivered by registered mail or facsimile to the Party(ies) at the
following addresses:
NMCG: Attention: Executive Director (Projects)

Address: 1st Floor, Major Dhyanchand National Stadium, India Gate, New Delhi - 110002
Tel: +91(11) 23049442
Fax: +91(11) 23049566
Email: ed.projects@nmcg.nic.in
Uttar Pradesh Jal Nigam:

Attention: Superintending Engineer, Construction Unit
Address: Uttar Pradesh Jal Nigam (Rural), Malhipur Road, YAP STP, Saharanpur Uttar Pradesh -
247001
Tel:
Fax:
Email: seupjnsre@yahoo.com
[Concessionaire]: [ ]
Escrow Bank: [ ]
6.3 Entire Agreement
This Escrow Agreement and the Concession Agreement constitutes the entire agreement and
understanding between the Parties with respect to its subject matter (i.e., escrow arrangement) and
replaces and supersedes all prior agreements, arrangements, undertakings or statements regarding
such subject matter.
6.4 Amendments
No variation of or amendment to this Escrow Agreement shall be effective unless made in writing
and executed by all the Parties hereto.
6.5 Harmonious Construction
48
For the purpose of giving full and proper effect to this Escrow Agreement, the Concession
Agreement and this Escrow Agreement shall be read together and construed harmoniously. The
terms of the Concession Agreement shall prevail in the event of any inconsistencies with this
Escrow Agreement.
6.6 Assignment
Neither this Escrow Agreement nor any of the rights or obligations hereunder may be assigned by
a Party without the prior written consent of the other Parties, provided that the Concessionaire shall
be entitled, to the extent permitted by Applicable Law and as may be required under any Financing
Documents entered into by the Concessionaire, to assign or create liens over its rights and interests
under or pursuant to this Escrow Agreement.
6.7 Severability
Whenever possible, each provision of this Escrow Agreement shall be interpreted in such a way as
to be effective and valid under Applicable Law, but if any provision of this Escrow Agreement is
unenforceable or invalid under Applicable Law, such provision shall be ineffective only to the
extent of such unenforceability or invalidity, and the remaining provisions of this Escrow
Agreement shall continue to be binding and in full force and effect.
6.8 Confidentiality
The Parties, their employees, representatives and agents shall keep the provisions of this Escrow
Agreement strictly confidential and, except as may be required by Applicable Laws, shall make no
disclosure thereof to any Person, except the Parties' respective legal counsels and professional
advisers, without the prior written consent of the other Parties.
6.9 Termination
This Escrow Agreement shall be automatically terminated upon the expiry of the Term or
termination of the Concession Agreement and after disbursement of all amounts due and payable
to the Concessionaire under the Concession Agreement, including Termination Compensation, if
any, and any remaining amounts due and payable to NMCG in accordance with Clauses 2.4(d) and
2.5(d) of this Escrow Agreement.
6.10 Dispute Resolution Mechanism
(a) If any dispute arises out of or in connection with this Escrow Agreement, this dispute shall
not affect the Parties' duty to continue the performance of all of their undisputed
obligations.
(b) If any dispute arises, a Party shall give written notice to the other Parties of the same,
whereupon the Parties shall meet promptly and in good faith to attempt to reach an amicable
settlement.
49
(c) All disputes not settled amicably pursuant to subparagraph (b) above shall be heard by the
competent courts of Uttar Pradesh.
6.11 Governing Law
This Escrow Agreement shall be governed by and construed in accordance with the laws of India.
IN WITNESS WHEREOF, the Parties hereto have caused the present to be executed by their authorized
representatives as of the date first written above.
For NMCG
By. ………………………..
Name: [ ]
Designation: [ ]
For Uttar Pradesh Jal Nigam

By. ………………………..
Name: [ ]
Designation: [ ]
For Concessionaire
By. ………………………..
Name: [ ]
Designation: [ ]
For Escrow Bank

By. ………………………..
Name: [ ]
Designation: [ ]
50
Schedule 4: Format of the Mobilization Advance Guarantee
[ON APPROPRIATE STAMP PAPER]
Guarantee No. : [●]

Amount of Guarantee : [●]
This Mobilization Advance Guarantee is executed on this [] day of [] at []
BY
[] with its registered office at [] and a branch office at [] (hereinafter referred to as the "Bank", which
expression shall unless repugnant to the context thereof, be deemed to include its successors-in-interest and
permitted assigns)
IN FAVOUR OF
Uttar Pradesh Jal Nigam (Rural), a statutory body constituted under the Uttar Pradesh Water Supply and
Sewerage Amendment Act, 1975, with its registered office at 6, Rana Pratap Marg, Lucknow - 226001
(hereinafter referred to as the "Jal Nigam", which expression shall unless repugnant to the context thereof,
be deemed to include its successors-in-interest and permitted assigns).
WHEREAS
A. [________________[insert name of the Concessionaire] with its registered office at

_______________________________ [insert address], hereinafter referred to as the
"Concessionaire", which expression shall unless repugnant to the context thereof, be deemed to
include its successors-in-interest and permitted assigns) has executed a concession agreement dated
[] with the Jal Nigam and National Mission for Clean Ganga ("Concession Agreement") in
relation to design, construction, operation and maintenance of sewage treatment plants along with
other facilities and associated infrastructure at Saharanpur, by the Concessionaire.
B. In terms of Clause 5.17 of the Concession Agreement, the Concessionaire is required to furnish a
Mobilization Advance Guarantee to the Jal Nigam in the form of an unconditional, irrevocable and
on demand bank guarantee for securing the Mobilization Advance made to the Concessionaire in
accordance with the Concession Agreement ("Mobilization AdvanceGuarantee") for INR [insert
amount] (Rupees []) ("Guaranteed Amount").
C. At the request of the Concessionaire and for sufficient consideration, the Bank has agreed to issue
this guarantee in favour of the Jal Nigam.
NOW THEREFORE THIS DEED WITNESSETH AS FOLLOWS:
1. Capitalised terms used herein but not defined shall have the meaning ascribed to them in the
Concession Agreement.
51
2. The Bank shall upon a written demand from the Jal Nigam informing the Bank of the
Concessionaire's failure to fulfill its obligations under the Concession Agreement, pay to the Jal
Nigam, within 5 (five) days of receipt of such written demand from the Jal Nigam, without further
proof or conditions and without contest, recourse, demur or protest and without any enquiry to the
Jal Nigam or the Concessionaire, forthwith and in full amount, without any deductions or set off or
counter claims whatsoever, the sum claimed by the Jal Nigam in such demand not exceeding an
amount equivalent to the Guaranteed Amount. The Bank will pay the amount specified in the
demand notwithstanding any direction to the contrary given or any dispute raised by the
Concessionaire or any other person.
The Bank agrees that this Mobilization Advance Guarantee does not limit the number of claims
that may be made by the Jal Nigam against the Bank provided that such claims taken together shall
not exceed the Guaranteed Amount.
Any payment made hereunder shall be made free and clear of and without deduction for, or on
account of, any present or future taxes, deductions or withholdings of any nature whatsoever and
by whomsoever imposed, and where any withholding on a payment is required by any Applicable
Law, the Bank shall comply with such withholding obligations and shall pay such additional
amount in respect of such payment such that the Jal Nigam receives the full amount due hereunder
as if no such withholding had occurred.
3. This Mobilization Advance Guarantee shall be a continuing guarantee during its currency and shall
remain in force and effect until the entire [Saharanpur Facilities] Mobilization Advance secured by
such Mobilization Advance Guarantee has been adjusted against the Saharanpur Facilities
Construction Payments, respectively.
4. The obligations of the Bank herein are absolute and unconditional, irrespective of the value,
genuineness, validity, regularity or enforceability of the Concession Agreement or the insolvency,
bankruptcy, reorganisation, dissolution or liquidation of the Concessionaire or any change in
ownership of the Concessionaire or any purported assignment by the Concessionaire or any other
circumstance whatsoever which might otherwise constitute a discharge or defence of a guarantor
or a surety.
Further, this Mobilization Advance Guarantee is in no way conditional upon any requirement that
the Jal Nigam first attempts to procure the Guaranteed Amount from the Concessionaire or any
other person, or resort to any other means of obtaining payment of the Guaranteed Amount.
5. The Bank hereby agrees that its liability under this Mobilization Advance Guarantee shall not be
discharged by virtue of any agreement between the Concessionaire and the Jal Nigam, whether
with or without the Bank's knowledge, or by reason of the Jal Nigam showing any indulgence or
forbearance to the Concessionaire.
6. The Bank's obligations under this Mobilization Advance Guarantee for the Guaranteed Amount is
primary, independent and absolute and not by way of surety only.
52
7. The obligations of the Bank under this Mobilization Advance Guarantee shall not be affected by
any act, omission, matter or thing which, but for this provision, would prejudice or diminish the
Guaranteed Amount in whole or in part, including (whether or not known to it or the Jal Nigam):
(a) any time or waiver granted to, or composition with, the Concessionaire or any other person;
(b) any incapacity or lack of powers, authority or legal personality of or dissolutions or change
in the status of the Concessionaire or any other person;
(c) any variation of the Concession Agreement so that references to the Concession Agreement
in this Mobilization Advance Guarantee shall include each variation;
(d) any unenforceability, illegality or invalidity of any obligation of any person under the
Concession Agreement or any unenforceability, illegality or invalidity of the obligations
of the Bank under this Mobilization Advance Guarantee or the unenforceability, illegality
or invalidity of the obligations of any person under any other document or guarantee, to
the extent that each obligation under this Mobilization Advance Guarantee shall remain in
full force as a separate, continuing and primary obligation, and its obligations be construed
accordingly, as if there were no unenforceability, illegality or invalidity;
(e) any extension, waiver, or amendment whatsoever which may release a guarantor or the
Bank (other than performance or indefeasible payment of a Guaranteed Amount); or
(f) any part performance of the Concession Agreement by the Concessionaire or by any failure
by the NMCG to timely pay or any failure by NMCG or the Jal Nigam to timely perform
any of its obligations under the Concession Agreement.
8. So long as any sum remains owing by the Concessionaire to the Jal Nigam, the Bank shall not
exercise any right of subrogation or any other rights of a guarantor or enforce any guarantee or
other right or claim against the Concessionaire (whether in respect of its liability under this
Mobilization Advance Guarantee or otherwise) or claim in the insolvency or liquidation of the
Concessionaire or any such other person in competition with the Jal Nigam. If the Bank receives
any payment or benefit in breach of this Clause 8, it shall hold the same in trust for the Jal Nigam.
9. The Bank represents, warrants and undertakes to the Jal Nigam that:
(a) it has the power to execute, deliver and perform the terms and provisions of this Mobilization
Advance Guarantee and has taken all necessary action(s) to authorize the execution, delivery
and performance by it of this Mobilization Advance Guarantee;
(b) the Bank has duly executed and delivered this Mobilization Advance Guarantee, and this
Mobilization Advance Guarantee constitutes its legal, valid and binding obligation
enforceable in accordance with its terms except as the enforceability thereof may be limited
by applicable bankruptcy, insolvency, moratorium or other similar laws affecting the
enforcement of creditors’ rights generally and by general equitable principles;
53
(c) neither the execution, delivery or performance by the Bank of this Mobilization Advance
Guarantee, nor compliance by it with the terms and provisions hereof will: (i) contravene
any material provision of any law, statute, rule or regulations or any order, writ, injunction
or decree of any court or governmental instrumentality; (ii) conflict or be inconsistent with
or result in any breach of any of the material terms, covenants, conditions or provisions of,
or constitute a default under any agreement, contract or instrument to which the Bank is a
party or by which it or any of its property or assets is bound; or (iii) violate any provision of
the Bank's constituent documents;
(d) no order, consent, approval, license, authorization or validation of, or filing, recording or
registration with (except as have been obtained or made prior to the date hereof), or
exemption by, any governmental or public body or authority, or any subdivision thereof, is
required to authorize, or is required in connection with: (i) the execution, delivery and
performance of this Mobilization Advance Guarantee; or (ii) the legality, validity, binding
effect or enforceability of this Mobilization Advance Guarantee; and
(e) this Mobilization Advance Guarantee will be enforceable when presented for payment to a
Scheduled Bank (as defined by the Reserve Bank of India Act, 1934) at Saharanpur.
10. This Mobilization Advance Guarantee is a continuing one and all liabilities to which it applies or
may apply under the terms hereof shall be conclusively presumed to have been created in reliance
hereon. No failure or delay on the part of the Jal Nigam in exercising any right, power or privilege
hereunder and no course of dealing between the Jal Nigam and the Bank, or the Concessionaire,
shall operate as a waiver thereof, nor shall any single or partial exercise of any right, power or
privilege hereunder preclude any other or further exercise thereof or the exercise of any other right,
power or privilege.
11. If any one or more of the provisions contained in this Mobilization Advance Guarantee are or
become invalid, illegal or unenforceable in any respect, the validity, legality and enforceability of
the remaining provisions shall not in any way be affected or impaired thereby, and the Bank shall
enter into good faith negotiations with the Jal Nigam to replace the invalid, illegal or unenforceable
provision.
12. The Bank hereby agrees to execute and deliver all such instruments and take all such actions as
may be necessary to make effective fully the purposes of this Mobilization Advance Guarantee.
13. This Mobilization Advance Guarantee may be executed in one or more duplicate counterparts, and
when executed and delivered by the Bank and the Jal Nigam shall constitute a single binding
agreement.
14. Any demand, notice, request or other communication to be given or made under this Mobilization
Advance Guarantee shall be deemed to have been duly given or served:
(a) Upon the Jal Nigam, at Construction Unit, UP Jal Nigam (Rural), Malhipur Road, YAP
STP, Saharanpur, Uttar-Pradesh – 247001;
54
(b) Upon a Scheduled Bank (as defined by the Reserve Bank of India Act, 1934), at
Saharanpur, India.
15. The Bank:
(a) acknowledges that the Lenders will review this Mobilization Advance Guarantee and may
require changes thereto as a condition of granting any Financial Assistance and/or
providing political risk insurance; and
(b) shall consider any such requirements in good faith.
16. This Mobilization Advance Guarantee shall be governed by, and construed in accordance with, the
laws of India. The Bank irrevocably agrees that any legal action, suit or proceeding arising out of
or relating to this Mobilization Advance Guarantee may be brought in the courts in Uttar Pradesh.
17. The Jal Nigam may assign or transfer all or any part of its interest herein together with the
Concession Agreement to any other person with prior consent of to the Bank. The Bank may not
assign or transfer any of its rights or obligations under this Mobilization Advance Guarantee.
IN WITNESS WHEREOF the Bank has set its hands hereunto on the day, month and year first
hereinabove written.
Signed and delivered by [insert name of Bank] Bank by hand
55
Schedule 5: Scope of Work of the Project Engineer and his team for the Facilities
The Project Engineer shall assist the Jal Nigam in supervising the construction, operation and maintenance
of the Facilities and shall work closely with the Jal Nigam to monitor compliance with the KPIs. The
detailed scope of work of the Project Engineer, to be read in conjunction with the provisions of the
Concession Agreement, is outlined below:
a) The Project Engineer shall review the Designs and Drawings to be provided by the Concessionaire.
These will include, inter-alia, the site layout plan, process design, drawings, structural calculations,
mechanical, electrical and instrumentation works, quality plans, implementation schedules,
operation and maintenance plans, and the environment, health & safety plans for all Facilities. On
the basis of its review, the Project Engineer shall provide its recommendations to the Jal Nigam.
b) During relevant Construction Periods, the Project Engineer shall inspect the relevant Facilities at
least once a month and prepare an inspection report, setting out the progress of the construction of
the relevant Facilities, defects or deficiencies, if any, and status of compliance with the
Construction Plan, Technical Specifications and Designs and Drawings and the Guaranteed Interim
Availability.
c) The Project Engineer shall be responsible to monitor the implementation of the approved
environment, health & safety plan by the Concessionaire. The Project Engineer shall also verify
the material safety data sheets of hazardous chemicals if any.
d) The Project Engineer shall review the construction progress of the project as per the Payment
Milestones proposed by the Concessionaire and provide necessary recommendations to the Jal
Nigam for the purpose of issuance of Milestone Construction Certificates.
e) The Project Engineer shall assist Jal Nigam in estimating the Delay Liquidated Damages as
applicable.
f) At the end of the Construction Period for different Facilities, the Project Engineer shall review the
relevant Facilities and provide necessary recommendations to the Jal Nigam with regards to the
issuance of the respective Construction Completion Certificates to the Concessionaire to certify
completion of construction of such Facilities, and the satisfaction of all other conditions required
to be fulfilled by the Concessionaire.
g) The Project Engineer shall monitor the Trial Operations of different Facilities during their
respective Trial Periods and provide necessary recommendations to the Jal Nigam for the purpose
of the issuance of the respective COD Certificates to the Concessionaire. The review shall be based
on the Trial Operations Procedures outlined in the Concession Agreement and include the
following.
 Verify quality of installations, operation of equipment and workmanship;
 Verify the Discharge Standard of the Treated Effluent, Treated Water and Facilities By-
Products;
 Verify the consumption of electricity and generation of power if any vis-à-vis the Guaranteed
Energy Consumption.
56
h) The Project Engineer shall review the O&M Manual and the Scheduled Maintenance Program
submitted by the Concessionaire and provide its recommendations to the Jal Nigam.
i) During the O&M Period, the Project Engineer shall inspect all the Facilities at least once a month
and prepare an inspection report, setting out the defects or deficiencies, if any, and status of
compliance with the relevant KPIs (including specifically, the Influent Standards and the Discharge
Standards).
j) The Project Engineer shall review the reports generated form the Online Monitoring Systems of
different Facilities to assess adherence to their relevant KPIs and submit the monthly KPI
Adherence Reports to the Jal Nigam.
k) The Project Engineer shall assist Jal Nigam in estimating the Availability Liquidated Damages, the
Performance Liquidated Damages and the Power Consumption Liquidated Damages as applicable.
l) The Project Engineer shall inspect laboratories where tests are conducted on samples to ensure
conformance and compliance with laboratory procedures and requirements.
m) During the Term, and as requested by the Jal Nigam, the Project Engineer shall provide its opinion
and assessment on the implications of the events related to Emergency, Change in Law, Force
Majeure, Fundamental Change in Law, Minor casualty, Total casualty, Variation and Unforeseen
Site Conditions.
n) The Project Engineer shall participate in the survey to determine the Hand-back Conditions as per
the Hand-back Requirements. It shall review the survey report of the Hand-back Conditions
submitted by the Concessionaire and provide its recommendations to the Jal Nigam on the
compliance with the Hand-back Requirements.
57
Schedule 6 – Liquidated Damages
1. Availability of Main Pumping Stations
Parameter Value
During construction period- Guaranteed Interim
--
Availability
Guaranteed Availability of pumping station in working
condition as per design and parameters defined in the 100%
contract agreement after COD
Hours in the month for which a specific pumping station was
not Available (A)
Non-Availability for the specific pumping station (B) =[(A) / 720] x100
LDs for non- adherence for the specific pumping station
= (B) x 2,000
(INR)
2. Availability of STP
Parameter Value
Guaranteed Availability of STP in working condition of all
units as per design and parameters defined in the contract 100%
agreement After COD - Guaranteed Availability
Hours in the month for which the relevant Facilities were not
----
Available (A)
= [(A) / 720] x100
Non-Availability (B)
LDs for non- adherence (INR) = (B) x 30,000
3. Treated Effluent and Digested/dewatered Sludge liquidated damages for each STP locations
Liquidated Damages
Parameter
(INR) per day
A. Liquidated Damages
BOD 5,000
COD 5,000
TSS 5,000
Nitrogen Total 5,000
Phosphorus Total 5,000
Fecal Coliform 5,000
B. Sludge to be disposed
Outlet Concentration of dewatered sludge 3,000
Volatile suspended solids 3,000
Faecal coliform 3,000
58
4. Biogas Production
Non-Compliance with Guaranteed value in 70 For every event of

Rs. 2000/Nm3 /day
Nm3/day (i.e. 90% system reliability) non- conformance*
* An event is defined as daily average production value, not meeting the guaranteed production
value in 10 samples in a month i.e. 90% system reliability.
59
Schedule 7: Applicable Permits
Concessionaire Applicable Permits
No. Applicable Permit Authority

1. Temporary Power Connection (During Electricity Board/ other temporary sources
Construction Period)
2. Consent to Operate State Pollution Control Board
3. Consent for storage of hazardous materials Director of Explosives
4. Consent Firefighting system Firefighting Department
5. CEIG approval – stage 1 for construction & Chief electrical inspector to Government
stage 2 on completion of project
6. Consent to Establish Labour Camp Labour Department
7. Consent for usage of water for construction Water Resources Department / Ground Water
purposes department
8. Consent for procurement/use of construction Department of Mines and Geology / State and/ or
materials such as sand, aggregates etc. from authorized suppliers
burrow areas.
The Concessionaire will be liable to obtain all Applicable Permits (other than the Jal Nigam Applicable Permits)
that are necessary for construction, operation and maintenance of the Facilities.
Jal Nigam shall assist the Concessionaire in obtaining all the required permits.
Jal Nigam Applicable Permits

S No. Applicable Permit Authority
1. Permanent Power Connection for operation of facilities Electricity Board

2. Layout and building plan approval ULB/DTCP
3. Consent to establish State Pollution Control Board (SPCB)
4. Tree cutting Forest Department
5. Road cutting & crossing Public Works Department
6. Railway Crossing Commissioner Railway safety
7. Revenue road cutting & crossing Panchayat/Local Authority
8. Obtaining No Objection Certificate for various ULB/District Administration
sewerage facilities under the ULB for handing them over
to [EXECUTING AGENCY]
9. Construction of weirs/pipeline crossings Irrigation Department/ULB
10. Approach Road to Facilities Forest Department/ Panchayat/Local
Authority/Irrigation Department
11. Consent to Operate for Existing Facilities ULB and SPCB
The Concessionaire shall proactively assist the Jal Nigam in obtaining all the required permits.
60
Schedule 8: EHS Standards
Part 1 – Link to the Environment and Social Management Framework (ESMF) to be followed for NGRBA
Projects
1. Environmental and Social Management Framework of NGRBA Project: http://nmcg.nic.in/Disclosure.aspx
Part 2 – The World Bank Group Safeguard Policies and Performance Standards
Given below are the links to relevant World Bank Group Safeguard Policies and Performance Standards with respect
to Environment, Social, Health and Safety requirements to be followed while developing the ESHS Documents -
2. WBG Safeguard Policies / Performance Standards:

https://policies.worldbank.org/sites/PPF3/Pages/Manuals/Operational%20Manual.aspx
3. WBG Guidance Note on Project Induced Labor Influx:

http://pubdocs.worldbank.org/en/497851495202591233/Managing-Risk-of-Adverse-impact-from-project-
labor-influx.pdf
Part 3 - Requirements for preparation of ESHS Management Strategies and Implementation Plans (ESHS-
MSIP)
The Concessionaire shall submit comprehensive and concise Environmental, Social, Health and Safety Management
Strategies and Implementation Plans (ESHS-MSIP). These strategies and plans shall describe in detail the actions,
materials, equipment, management processes etc. that will be implemented by the Concessionaire, and its
subcontractors.
In developing these strategies and plans, the Concessionaire shall have regard to the ESHS provisions of the
Concession Agreement including those as may be more fully described in the following:
a. Works Requirements described in Concession Agreement;
b. Environmental and Social Impact Assessment (ESIA);
c. Environmental and Social Management Plan (ESMP);
d. Consent Conditions (regulatory authority conditions attached to any permits or approvals

for the project).
…………………………………………………………………………………………………
Metrics for Progress Reports
The following Metrics should be used for regular reporting:
a. environmental incidents or non-compliances with Concession Agreement requirements, including

contamination, pollution or damage to ground or water supplies;
b. health and safety incidents, accidents, injuries and all fatalities that require treatment;
c. interactions with regulators: identify agency, dates, subjects, outcomes (report the negative if none);
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d. status of all permits and agreements:
i. work permits: number required, number received, actions taken for those not received;
ii. status of permits and consents:
o list areas/facilities with permits required (quarries, asphalt & batch plants), dates of application, dates
issued (actions to follow up if not issued), dates submitted to resident engineer (or equivalent), status
of area (waiting for permits, working, abandoned without reclamation, decommissioning plan being
implemented, etc.);
o list areas with landowner agreements required (borrow and spoil areas, camp sites), dates of
agreements, dates submitted to resident engineer (or equivalent);
o identify major activities undertaken in each area this month and highlights of environmental and social
protection (land clearing, boundary marking, topsoil salvage, traffic management, decommissioning
planning, decommissioning implementation);
o for quarries: status of relocation and compensation (completed, or details of monthly activities and
current status).
e. health and safety supervision:
iii. safety officer: number days worked, number of full inspections & partial inspections, reports to
construction/project management;
iv. number of workers, work hours, metric of PPE use (percentage of workers with full personal protection
equipment (PPE), partial, etc.), worker violations observed (by type of violation, PPE or otherwise),
warnings given, repeat warnings given, follow-up actions taken (if any);
f. worker accommodations:
i. number of expats housed in accommodations, number of locals;
ii. date of last inspection, and highlights of inspection including status of accommodations’ compliance with
national and local law and good practice, including sanitation, space, etc.;
iii. actions taken to recommend/require improved conditions, or to improve conditions.
g. HIV/AIDS: provider of health services, information and/or training, location of clinic, number of non-safety
disease or illness treatments and diagnoses (no names to be provided);
h. gender (for expats and locals separately): number of female workers, percentage of workforce, gender issues
raised and dealt with (cross-reference grievances or other sections as needed);.
i. training:
i. number of new workers, number receiving induction training, dates of induction training;
ii. number and dates of toolbox talks, number of workers receiving Occupational Health and Safety (OHS),
environmental and social training;
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iii. number and dates of HIV/AIDS sensitization training, no. workers receiving training (this month and in
the past); same questions for gender sensitization, flaglady/flagman training.
j. environmental and social supervision:
i. environmentalist: days worked, areas inspected and numbers of inspections of each part of the Facilities
created, highlights of activities/findings (including violations of environmental and/or social best practices,
actions taken), reports to environmental and/or social specialist/construction/site management;
ii. sociologist: days worked, number of partial and full site inspections of each part of the Facilities created,
highlights of activities (including violations of environmental and/or social requirements observed, actions
taken), reports to environmental and/or social specialist/construction/site management; and
iii. community liaison person(s): days worked (hours community center open), number of people met, highlights
of activities (issues raised, etc.), reports to environmental and/or social specialist /construction/site
management.
k. Grievances: list this month’s and unresolved past grievances by date received, complainant, how received, to
whom referred to for action, resolution and date (if completed), data resolution reported to complainant, any
required follow-up (Cross-reference other sections as needed):
i. Worker grievances;
ii. Community grievances
l. Traffic and vehicles/equipment:
i. traffic accidents involving project vehicles & equipment: provide date, location, damage, cause, follow-
up;
ii. accidents involving non-project vehicles or property (also reported under immediate metrics): provide
date, location, damage, cause, follow-up;
iii. overall condition of vehicles/equipment (subjective judgment by environmentalist); non-routine repairs

and maintenance needed to improve safety and/or environmental performance (to control smoke, etc.).
m. Environmental mitigations and issues (what has been done):
i. dust: number of working bowsers, number of waterings/day, number of complaints, warnings given by
environmentalist, actions taken to resolve; highlights of quarry dust control (covers, sprays, operational
status); % of rock/muram/spoil lorries with covers, actions taken for uncovered vehicles;
ii. erosion control: controls implemented by location, status of water crossings, environmentalist
inspections and results, actions taken to resolve issues, emergency repairs needed to control
erosion/sedimentation;
iii. quarries, borrow areas, spoil areas, asphalt plants, batch plants: identify major activities undertaken
this month at each, and highlights of environmental and social protection: land clearing, boundary
marking, topsoil salvage, traffic management, decommissioning planning, decommissioning
implementation;
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iv. blasting: number of blasts (and locations), status of implementation of blasting plan (including notices,
evacuations, etc.), incidents of off-site damage or complaints (cross-reference other sections as needed);
v. spill cleanups, if any: material spilled, location, amount, actions taken, material disposal (report all
spills that result in water or soil contamination);
vi. waste management: types (say municipal C&D, hazardous, water, etc.) and quantities generated and
managed, including amount taken offsite (and by whom) or reused/recycled/disposed on-site;
vii. details of tree plantings and other mitigations required undertaken this month;
viii. details of water and swamp protection mitigations required undertaken this month.
n. compliance:
i. compliance status for conditions of all relevant consents/permits, for the Work, including quarries, etc.):
statement of compliance or listing of issues and actions taken (or to be taken) to reach compliance;
ii. compliance status of ESMP/ESIP requirements: statement of compliance or listing of issues and actions
taken (or to be taken) to reach compliance
iii. other unresolved issues from previous months related to environmental and social: continued violations,
continued failure of equipment, continued lack of vehicle covers, spills not dealt with, continued
compensation or blasting issues, etc. Cross-reference other sections as needed.
Part 4 – Requirements for the preparation of the Code of Conduct

The Concessionaire shall submit the Code of Conduct that will apply to the Concessionaire’s employees and
subcontractors. The Code of Conduct shall ensure compliance with the ESHS provisions of the Concession
Agreement, including those as may be more fully described in the following:
a. Works Requirements described in Concession Agreement;
b. Environmental and Social Impact Assessment (ESIA);
c. Environmental and Social Management Plan (ESMP);
d. Consent Conditions (regulatory authority conditions attached to any permits or approvals for the project).
MINIMUM REQUIREMENTS FOR THE CODE OF CONDUCT
A minimum requirement for the Code of Conduct should be set out, taking into consideration the issues, impacts,
and mitigation measures identified in:
 project reports e.g. ESIA/ESMP
 consent/permit conditions
 required standards including World Bank Group EHS Guidelines and Performance Standards
 national legal and/or regulatory requirements and standards (where these represent higher standards than
the WBG EHS Guidelines and PS)
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 relevant standards e.g. Workers’ Accommodation: Process and Standards (Indian Standards, and in the
absence of such Indian Standards those of IFC and EBRD)
 relevant sector standards e.g. workers accommodation
 grievances redress mechanisms.
The types of issues identified could include risks associated with: labor influx, spread of communicable diseases,
sexual harassment, gender based violence, illicit behavior and crime, and maintaining a safe environment etc.
A satisfactory code of conduct will contain obligations on all project staff (including sub-contractors and day
workers) that are suitable to address the following issues, as a minimum.
Compliance with applicable laws, rules, and regulations of the jurisdiction
1. Compliance with applicable health and safety requirements (including wearing prescribed personal
protective equipment, preventing avoidable accidents and a duty to report conditions or practices that pose
a safety hazard or threaten the environment)
2. The use of illegal substances
3. Non-Discrimination (for example on the basis of family status, ethnicity, race, gender, religion, language,
marital status, birth, age, disability, or political conviction)
4. Interactions with community members (for example to convey an attitude of respect and non-discrimination)
5. Sexual harassment (for example to prohibit use of language or behavior, in particular towards women or
children, that is inappropriate, harassing, abusive, sexually provocative, demeaning or culturally
inappropriate)
6. Violence or exploitation (for example the prohibition of the exchange of money, employment, goods, or
services for sex, including sexual favors or other forms of humiliating, degrading or exploitative behavior)
7. Protection of children (including prohibitions against abuse, defilement, or otherwise unacceptable behavior
with children, limiting interactions with children, and ensuring their safety in project areas)
8. Sanitation requirements (for example, to ensure workers use specified sanitary facilities provided by their
employer and not open areas)
9. Avoidance of conflicts of interest (such that benefits, Concession Agreement, or employment, or any sort
of preferential treatment or favors, are not provided to any person with whom there is a financial, family, or
personal connection)
10. Respecting reasonable work instructions (including regarding environmental and social norms)
11. Protection and proper use of property (for example, to prohibit theft, carelessness or waste)
12. Duty to report violations of this Code
13. Non retaliation against workers who report violations of the Code, if that report is made in good faith.
The Code of Conduct should be written in plain language and signed by each worker to indicate that they have:
 received a copy of the code;
 had the code explained to them;
 acknowledged that adherence to this Code of Conduct is a condition of employment; and
 understood that violations of the Code can result in serious consequences, up to and including dismissal, or
referral to legal authorities.
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Code of Conduct for Concessionaire’s Personnel (ES)Form
Note to the Employer:

The following minimum requirements shall not be modified. The Employer may add
additional requirements to address identified issues, informed by relevant environmental
and social assessment.
The types of issues identified could include risks associated with labour influx, spread of
communicable diseases, and Sexual Exploitation and Abuse (SEA)etc.
Delete this Box prior to issuance of the bidding documents
Note to the Concessionaire:
The minimum content of the Code of Conduct form as set out by the Employer shall
not be substantially modified. However, the Concessionaire may add requirements as
appropriate including to take into account Contract-specific issues/risks.
The Concessionaire shall initial and submit the Code of Conduct form as par to fits bid.
We are the Concessionaire, [enter name of Concessionaire]. We have signed a Concession

Aggrement with [enter name of Employer] for [enter description of the Works]. These Works will
be carried out at [enter the Site and other locations where the Works will be carried out]. Our
contract requires us to implement measures to address environmental and social risks related to the
Works, includingtherisksofsexualexploitationandassaultandgender-basedviolence.
This Code of Conduct is part of our measures to deal with environmental and social risks related to
the Works. It applies to all our staff, labourers and other employees at the Works Site or other places
where the Works are being carried out. It also applies to the personnel of each subcontractor and any
other personnel assisting us in the execution of the Works. All such persons are referred to as
“Concessionaire’s Personnel” and are subject to this Code of Conduct.
This Code of Conduct identifies the behaviour that we require from all Concessionaire’s Personnel.
Our workplace is an environment where unsafe, offensive, abusive or violent behaviour will not be
tolerated and where all persons should feel comfortable raising issues or concerns without fear of
retaliation.
REQUIRED CONDUCT
Concessionaire’s Personnel shall:

1. Carry out his/her duties competently and diligently
2. comply with this Code of Conduct and all applicable laws, regulations and other
requirements, including requirements to protect the health, safety and well-being of other
Concessionaire’s Personnel and any other person
3. maintain as a safe working environment including by:
a. ensuring that workplaces, machinery, equipment and processes under each person’s
control are safe and without risk to health
b. wearing required personal protective equipment
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c. using appropriate measures relating to chemical, physical and biological substances
and agents; and
d. following applicable emergency operating procedures.
4. report work situations that he/she believes are not safe or healthy and remove himself /
herself from a work situation which he/she reasonably believes presents an imminent and
serious danger tohis/her life or health
5. treat other people with respect, and not discriminate against specific groups such as women,
people with disabilities, migrant workers or children
6. not engage in any form of sexual harassment including unwelcome sexual advances, requests
for sexual favours, and other unwanted verbal or physical conduct of a sexual nature with
other Concessionaire’s or Employer’s Personnel
7. not engage in Sexual Exploitation, which means any actual or attempted abuse of position
of vulnerability, differential power or trust, for sexual purposes, including, but not limited
to, profiting monetarily, socially or politically from the sexual exploitation of another. In
Bank financed projects, sexual exploitation occurs when access to or benefit from Bank
financed Goods, Works, Consulting or Non-consulting services is used to extract sexual
gain
8. not engage in Sexual Abuse, which means sexual activity with another person who does not
consent. It is a violation of bodily integrity and sexual autonomy and is broader than
narrower conceptions of “rape”, especially because (a) it may be committed by other means
than force or violence, and (b) it does not necessarily entail penetration.
9. not engage in any form of sexual activity with individuals under the age of 18, except in
case of pre-existing marriage
10. completerelevanttrainingcoursesthatwillbeprovidedrelatedtotheenvironmentaland social
aspects of the Contract, including on health and safety matters, and Sexual Exploitation, and
Abuse (SEA)
11. report violations of this Code of Conduct; and
12. not retaliate against any person who reports violations of this Code of Conduct, whether to
us or the Employer, or who makes use of the [Project Grievance Redress Mechanism].
RAISING CONCERNS
If any person observes behaviour that he/she believes may represent a violation of this Code of
Conduct, or that otherwise concerns him/her, he/she should raise the issue promptly. This can be
done in either of the following ways:
1. Contact [enter name of the Concessionaire’s Social Expert with relevant experience in
handling gender-based violence, or if such person is not required under the Contract, another
individual designated by the Contractor to handle these matters] in writing at this address [ ]
or by telephone at[ ]or in person at [ ];or
2. Call [] to reach the Concessionaire’s hotline (if any) and leave a message.
The person’s identity will be kept confidential, unless reporting of allegations is mandated by the
country law. Anonymous complaints or allegations may also be submitted and will be given all due
and appropriate consideration. We take seriously all reports of possible misconduct and will
investigate and take appropriate action. We will provide warm referrals to service providers that
may help support the person who experienced the alleged incident, as appropriate.
There will be no retaliation against any person who raises a concern in good faith about any
behaviour prohibited by this Code of Conduct. Such retaliation would be a violation of this Code of
Conduct.
CONSEQUENCES OF VIOLATING THE CODE OF CONDUCT
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Any violation of this Code of Conduct by Concessionaire’s Personnel may result in serious
consequences, up to and including termination and possible referral to legal authorities.
FOR CONTRACTOR’S PERSONNEL:
I have received a copy of this Code of Conduct written in a language that I comprehend. I understand
that if I have any questions about this Code of Conduct, I can contact [enter name of Contractor’s
contact person with relevant experience in handling gender-based violence] requesting an
explanation.
Name of Concessionaire’s Personnel: [insert name]
Signature:
Date:(day /month/year):
Counter signature of authorized representative of the Concessionaire:

Signature: Date:(day / month / year)
Labour Issues
Mitigation and Management of Labour Issues:
The Concessionaire has to follow the Labour Management Procedure (LMP)which includes the
Employment conditions, labour welfare measures and Occupational Health & Safety of workforce. It is
intended to integrate the environmental, social, occupational health and safety principles of Indian national
and state regulations which clearly spell out the requirements relating to provision of terms and conditions
of employment; promoting of non-discrimination and equal opportunity; worker’s organization.
The Concessionaire has to obtain necessary Labour license prior to engaging labourers and
commencement of work and comply all the conditions stipulated in the license. The copy of labour license
will be submitted to the Engineer/Employer. The Primary Concessionaire will be responsible for
compliance of all the labour regulations including those of sub-contractor’s labours.
The Government of India/ State criteria for minimum age, wage and living provisions, benefits, hours of
work, overtime arrangements and overtime compensation, and leave for illness, maternity, vacation or
holiday should be met for all workers. The Concessionaire will conform to national law in relation to
hiring and employment; and will comply with the principle of equal opportunity, fair treatment, and non-
discrimination with respect to the employment relationship, gender, caste, races, etc.
The Concessionaire has to display a copy of the certificate of registration at the conspicuous place at the
premises where the building and other construction work is being carried on. A labour information sign
board is required to be established at camp site indicating payment of wage dates, working hours, holidays,
wages rates for different categories of labours and name and contact details of local labour inspector and
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office and emergency contact numbers. A procedure for receiving grievances on working issue is required
to be established in order to address the labour related issues. The Concessionaire will maintain muster
roll-cum-wages register for all the staff as per Labour rules including their own labourers engaged by any
means as well as sub-contractor’s labourers.
The PMU will periodically monitor the labour license, labour register, incidence register, etc. related to
labour issues.
The Concessionaire shall prepare monthly statement of different categories of labours engaged for various
construction activities and submit it to the PMU. The following format may be utilised for preparation of
monthly labour statement:
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Monthly Statement of Labourers Engaged
Name of the Project: Filled by:

Name of the Concessionaire: Date:
Name of PMU:
Reporting Month:
Local Labour Employed Migrant Labours (Man Total
(Man Days) Days) Local Percentage
Sub Male Female Total Male Female Total
Project Labours labours and of Local
Labours Labours labours Labours Migrated Labours(A
(A) (B) Labours /C*100)
(C)
Note: Skilled / Unskilled labour hired from Project influence area are called Local Labour.
They are hired on daily wages basis and generally not required any accommodation at
workplace.
Labour Influx:
Labor Influx and Construction Workers Camp Management Plan
During implementation phase, worker population is likely to influx in the project area. Management of this
labour influx and of issues related to the labour campsite are a critical part of environmental and social
management of the project. To address the probable impact due to labour influx, and establishment of
labour / workers camp, a detail camp management plan is prepared to minimize and mitigate the
environment and social impact.
Concessionaire’s Responsibility to Manage Labour Influx
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As a part of Concessionaire’s ESHS Plan, the contractor, within 14 days from the delivery of the Letter of
Acceptance, shall prepare and submit Labour Influx and Workers’ Camp Management Plan to the Project
Manager that addresses specific activities that will be undertaken to minimize the impact on the local
community, including elements such as workers’ code of conduct, training programs on HIV/AIDS, etc. A
Workers’ Camp Management Plan addresses specific aspects of the establishment and operation of
workers’ camps
This Labor Influx and Worker’s Camp Management Plan will include:
i.mandatory and repeated training and awareness raising for the workforce about refraining from
unacceptable conduct toward local community members, specifically women;
ii.informing workers about national laws that make sexual harassment and gender-based violence
a punishable offence which is prosecuted;
iii.introducing a Worker Code of Conduct as part of the employment contract, and including
sanctions for non-compliance (e.g., termination), manual scavenging, engagement with local
residents, child labor, nondiscrimination, harassment of coworkers including women and those
belonging to SC and STs and other minority social groups,
iv. Concessionaire adopting a policy to cooperate with law enforcement agencies in investigating
complaints about gender-based violence.
v.training programs on HIV/AIDS and other communicable diseases,
vi.workers’ Camp Management Plan addressing specific aspects of the establishment and
operation of workers’ camps provided the ULB/ Executing Agency is unable to cater to the
demand for affordable housing for this additional workforce in terms of rentals, hostels,
apartments etc.; and
vii.compliant handling Mechanism at the project level
Additional measures that aim to reduce incentives to engage with the local community by providing
workers with the opportunity to spend their time off away from the host community, where feasible with a
small transport allowance, ideally allowing workers to regularly return for brief visits to their families,
spouses and friends, or to visit nearby urban centers that provide a variety of legal social opportunities. For
workers who need to travel further it may be attractive to forego weekends off in exchange for longer
breaks that would allow for such home leave travel.
Model Code of Conduct (ESHS) for Concessionaire’s Employees and subcontractors
This Code of Conduct will oblige all Concessionaire’s Personnel (including sub-contractors and day
workers) to abide by following practices, as a minimum. Additional obligations may be imposed during
project implementation to respond to particular concerns of the region, the location and the project
sector or to specific project requirements. Concessionaire may also impose any additional or strengthen
code of conduct on his workers/ staff.
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The Code of Conduct should be written in plain language and signed by each worker to indicate that
they have:
o received a copy of the code;

o had the code explained to them;
o acknowledged that adherence to this Code of Conduct is a condition of employment; and
o understood that violations of the Code can result in serious consequences, up to and including
dismissal, or referral to legal authorities.
A copy of the code of conduct will be displayed at prominent locations easily accessible to the
community and project affected people. Name and contact number of the authorized representative of
the Concessionaire competent to attend the grievances of the local community or project affected
persons should also be provided on the display board, in languages comprehensible to the local
community, Project Manager’s Personnel, and Employer’s Personnel.
The model code of conduct:
None of Employees of the Concessionaire and the Subcontractor shall be involved in the
following activities:
o Burning of vegetation waste in open space.

o Unauthorized storage of inflammable substances or harmful non-desired chemical/ pesticide in labour
camp or work site.
o Harm or disturbance (including hunting/ poaching) to any endangered or threatened species
o Harm or disturbance to any culturally significant site.
o Unauthorized removal of timber.
o Disposal of solid or liquid wastes in river/canal, water bodies, streams, etc
o Illicit or criminal activities including sexual harassment of women or children (prohibit use of language
or behavior, in particular towards women and/or children, that is inappropriate, harassing, abusive,
sexually provocative, demeaning or culturally inappropriate).
o Violence including sexual and/or gender-based violence (for example acts that inflict physical, mental
or sexual harm or suffering, threats of such acts, coercion, and deprivation of liberty
o Exploitation including sexual exploitation and abuse (for example the prohibition of the exchange of
money, employment, goods, or services for sex, including sexual favours or other forms of humiliating,
degrading behaviour, exploitative behaviour or abuse of power).
o Use of illegal substances and consumption of intoxicating materials
o Discrimination in dealing with the local community (including vulnerable and disadvantaged groups),
Project Manager’s Personnel, Employer’s Personnel and also among themselves on the basis of family
status, ethnicity, race, gender, religion, language, marital status, age, disability (physical and mental),
sexual orientation, gender identity, political conviction or social, civic, or health status
o Open defecation
o Retaliation of workers who report violations of the Code, if that report is made in good faith.
o Fishing practice at the worksite on riverbed, and also in local or community ponds.
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Criteria as shown in Table below shall be considered for selection of camp site.
Table 1: Criteria for selecting camp site
Avoidance Preference
1. Lands within 300 m of residential area and 1. Waste land other than Low lying lands,
200 m of schools and health care centres; marshy areas;
2. Irrigated agricultural land; 2. Lands belonging to owners who look upon
3. Lands under village forests; the temporary use as a source of income;
4. Lands within 100 m of community water 3. Community lands or government land not
bodies, water sources such as rivers and also used for beneficial purposes;
other water courses; 4. Private non-irrigated lands where the
5. Low lying lands, marshy areas; owner is willing; and
6. Lands supporting dense vegetation 5. Lands with an existing access road
7. Lands where there is no willingness of the
landowner to permit its use.
Various management policies to be followed during site selection, facilities to be provided, Hygiene and
Sanitation, Arrangements for Waste Disposal, health care management, Storage of cement & fuel, Other
Safety and Security Measures have been shown in Table E.11 below.
Table 2: Camp Site Management Plan
Pre-Construction Stage
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Site Selection:
1. Identify the site for construction camp in consultation with the individual owners in
case of private lands and the Gram Panchayat / concerned Dept. in case of government
lands. Preference should be given to uncultivated fallow land / government land during
site selection;
2. In case, no government land / fallow and unutilized government land is available and
where use of private land is the only alternative, necessary arrangements should be
worked out with the private owner of the land for setting up of facilities during the
construction. The arrangement should have both facility creation and site restoration
(pre-construction stage) component.
3. The contractor shall produce No Objection Certificate from the concerned land owing/
managing authority/ person in case of setting up of Labour Camp outside the Govt.
Land under possession of the Employer.
4. A detailed layout plan should be prepared for the development of construction camp,
indicating the various structures to be constructed including the temporary structures
to be put up, site roads, drainage, lighting and other facilities and arrangements to be
made for restoration of the original characters of land after disbandment of the camp
and that should be submitted to the Project Manager
5. It should be ensured that there is no use of hazardous construction materials such as
Asbestos Containing Materials (ACM) in the construction of the camp.
6. Provision of free of cost temporary living in the camp site for all the workers employed
by contractor for the total work period.
Facilities to be Provided at the Camp Site:
1. The camp should have adequate space for accommodating the workers. In case of
women workers and families, the accommodation units should provide adequate
privacy.
2. The camp should have all common minimum required facilities like ventilation, bed /
bed roll for the workers, electricity supply, water supply, kitchen, separate toilet and
bathrooms for ladies and gents, etc.
3. Identification of potable drinking water source/s and seeking permission from local
authority / GP for accessing the source. In case, potable drinking water source is not
available in the vicinity, provision of water filter should be made in the camps to make
water potable.
4. Storage of drinking water should be made in cleaned / hygienic containers and should
be placed at a distance of not less than 15m from any wastewater / sewage drain, toilet
or other source of pollution.
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Hygiene and Sanitation:
1. Suitable washing facility for clothes and utensils at the camp level, with mechanism
for proper draining and disposal of wastewater.
2. Separate bathing facility for male and female workers in conveniently accessible
locations and shall be kept in clean and hygienic conditions.
3. Sanitary arrangements, latrines and urinals in every workplace. The type of latrine
chosen must be culturally appropriate / acceptable. The latrines must be suitable for
use in shallow groundwater / flood prone areas.
4. Separate toilet facility for male and female works with proper sign board in language
that are understood by the workers along with picture.
5. For 15-20 female and male workers, separate toilet provision should be made.
6. The latrines and urinals shall be adequately lighted and hygienic condition shall be
maintained (proper cleaning and sanitization).
7. Water shall be provided in or near the latrines and urinals (piped water or by storing
water in drums).
Arrangements for Waste Disposal:
1. Disposal of sanitary wastes and excreta shall be into septic tanks. Dry sanitation (toilet)
facility shall be provided at flood prone area.
2. Kitchen wastes (excluding solid waste) shall be disposed into soak pits. Wastewater
from campsites will be discharged and disposed in a kitchen soak pit located at least
15 meters away from any waterbody.
3. Capacity of the pit should be at least 1.3 times the maximum volume of wastewater
discharged per day.
4. The bottom of the soak pit should be filled with coarse gravel and the sides shored up
with board, etc. to prevent erosion and collapse of the soak pit.
5. Solid wastes generated in the construction site shall be reused if recyclable or disposed-
off in land fill sites approved by local authority.
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Health Care Management:
1. Availability of first aid box / facilities with all recommended medicines / non-
consumables in each construction site.
2. An educated person in the camp site should be oriented on administering first aid
treatment and the box should be placed under his/her command.
3. Arrangement should be made by which she/he would be available at the time of
requirement.
4. In case of any eventuality which demand hospitalization, transport facility should be
provided using available project vehicle or immediate transportation through
ambulance service to nearby health facility.
5. Periodic visit by a qualified medical doctor (PHC/CHC/SDH etc.) to the campsite for
health check-up of workers, at least once in 15 days. A register of all health problems
must be maintained by the doctor and available at the campsite.
6. Provision of health insurance of all workers for stipulated period of their engagement
in construction sites.
Storage of Fuel:
1. Storage site within the camp should be at a minimum distance of 30 meter from the
living area of the workers.
2. Liquids like oil / fuel / lubricants etc. should be stored at a height from the ground level
for which a brick-based platform with sand flooring should be prepared to avoid soil
and water contamination due to spillage.
Other Safety and Security Measures
1. Provision of fire extinguishers / Fire-fighting arrangements at the camps. Each area

shall be earmarked based on fire zone category (Fire zone- 1, 2 & 3). Arrangement
shall be available at each facility like living area, material storage area, hazardous
building. At least one fire lift and water storage tank shall also be provided at each
camp site.
2. Display of fire station number in prominent place for easy visibility.
3. In case the campsite has a common kitchen facility, it must be ensured that the common
kitchen (and any other kitchens in the campsite) is located at least 20 m away from the
living area. Only LPG stoves are to be used. Use of fuelwood stoves shall not be
permitted for use in camp site.
4. Provision of identity cards to labourers and residents of construction camps.
Construction Phase
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1. Construction camps shall be maintained free from litter and in hygienic condition.
2. It should be kept free from spillage of oil, grease or bitumen.
3. Any spillage should be cleaned immediately to avoid pollution of soil, water stored or
adjacent water bodies.
4. Precautions need to be taken in construction camps are like (1) no leaching of oil and
grease into water bodies or water sources, including canals take place; (2) non-disposal
of wastewater into water bodies; (3) collection and appropriate disposal of solid wastes
on regular basis; (4) hygienic condition of the toilet, its regular maintenance and
keeping it clean and (5) availability of first-aid care provision in the camp, (6) display
of emergency numbers (fire, police, ambulance, medical hospital etc,) in a common
place visible to others.
Post-Construction Phase
1. At the completion of construction, all construction camp facilities shall be dismantled

and removed from the site.
2. The site shall be restored to a condition in no way inferior to the condition prior to
commencement of the works.
3. Various activities to be carried out for site restoration are like (1) cleaning / removal
of oil and fuel contaminated soil and its disposal in approved waste disposal areas. (2)
construction campsite shall be grassed and planted with trees as per the restoration
design; (3) Sealing / filling up of soak pits and septic tanks; (4) disconnection of
electricity supply; (5) disposal of all garbage in the disposal site only (site approved
by local authority).
Measures to be taken for addressing issues related to COVID 19
The COVID-19 pandemic presents unprecedented challenges, and those circumstances require a highly
adaptive responsive management design to avoid, minimize and manage in this rapidly evolving situation.
This Project’s ESMF provides guidance in addressing key issues associated with COVID-19. This section
emphasizes the importance of careful scenario planning, clear procedures and protocols, management
systems, effective communication and coordination, and the need for high levels of responsiveness.
Key Challenges:
Though this project (Second National Ganga River Basin Project-SNGRBP) will not require big labour
camps, still there will be approximately 200 at the peak time. The skilled labour may come from outside
the district or project site whereas unskilled labour will be largely local. Still, they may need to live in
labour camps even though if they return to their homes after work. The camp may also see traffic from
suppliers and service providers on regular basis which will have the potential for the spread of infectious
disease in projects. Impact on the project workers may lead to additional burden on the local health services
which certainly will not be able to take the additional load.
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Concessionaire’s Responsibility:
The contract document generally has the clauses for health and safety of the workers but does not cover
pandemic situation. In SNGRBP, the Concessionaire will be required:
• to take all necessary precautions to maintain the health and safety of the Concessionaire’s Personnel
• to appoint a health and safety officer at site, who will have the authority to issue directives for the purpose
of maintaining the health and safety of all personnel authorized to enter and or work on the site and to
take protective measures to prevent accidents
• to ensure, in collaboration with local health authorities, that medical staff, first aid facilities, sick bay,
ambulance services and any other medical services specified are available at all times at the site and at
any accommodation
• to ensure suitable arrangements are made for all necessary welfare and hygiene requirements and for the
prevention of epidemics
• to provide health and safety training for Concessionaire’s Personnel (which include project workers and
all personnel that the Concessionaire uses on site, including staff and other employees of the
Concessionaire and Subcontractors and any other personnel assisting the Concessionaire in carrying out
project activities)
• to put in place workplace processes for Concessionaire’s Personnel to report work situations that are not
safe or healthy
• gives Concessionaire’s Personnel the right to report work situations which they believe are not safe or
healthy, and to remove themselves from a work situation which they have a reasonable justification to
believe presents an imminent and serious danger to their life or health (with no reprisal for reporting or
removing themselves)
• requires measures to be in place to avoid or minimize the spread of diseases including measures to avoid
or minimize the transmission of communicable diseases that may be associated with the influx of
temporary or permanent contract-related labor
• to provide an easily accessible grievance mechanism to raise workplace concerns
Specifically, Concessionaire shall
o prepare a detailed profile of the project work force, key work activities, schedule for
carrying out such activities, different durations of contract and rotations.
o Consideration should be given to ways in which to minimize movement in and out of site.
This could include lengthening the term of existing contracts, to avoid workers returning
home to affected areas, or returning to site from affected areas.
o Workers accommodated on site should be required to minimize contact with people near
the site, and in certain cases be prohibited from leaving the site for the duration of their
contract, so that contact with local communities is avoided.
o Consideration should be given to requiring workers lodging in the local community to
move to site accommodation (subject to availability) where they would be subject to the
same restrictions.
78
o Workers from local communities, who return home daily should be subject to health checks
at entry to the site.
o Establishing a system for controlling entry/exit to the site, securing the boundaries of the
site, and establishing designating entry/exit points (if they do not already exist). Entry/exit
to the site should be documented.
o Training security staff on the (enhanced) system that has been put in place for securing the
site and controlling entry and exit, the behaviors required of them in enforcing such system
and any COVID -19 specific considerations.
o Training staff who will be monitoring entry to the site, providing them with the resources
they need to document entry of workers, conducting temperature checks and recording
details of any worker that is denied entry.
o Confirming that workers are fit for work before they enter the site or start work.
o COVID-19 related issues to be part of daily toolbox talk such as cough etiquette, hand
hygiene and distancing measures, using demonstrations and participatory methods.
o During toolbox talk, reminding workers to self-monitor for possible symptoms (fever,
cough) and to report to their supervisor or the COVID-19 focal point if they have symptoms
or are feeling unwell.
o Preventing a worker from an affected area or who has been in contact with an infected
person from returning to the site for 14 days or (if that is not possible) isolating such worker
for 14 days.
o Preventing a sick worker from entering the site, referring them to local health facilities if
necessary or requiring them to isolate at home for 14 days.
o Training workers and staff on site on the signs and symptoms of COVID-19, how it is
spread, how to protect themselves (including regular handwashing and social distancing)
and what to do if they or other people have symptoms.
o Placing posters and signs around the site, with images and text in local languages.
o Ensuring handwashing facilities supplied with soap, disposable paper towels and closed
waste bins exist at key places throughout site, including entry /exits points, toilet, canteen
/ mess, drinking water points; worker accommodation; stores; and common spaces. Where
handwashing facilities do not exist or are not adequate, arrangements should be made to
set them up. Alcohol based sanitizer (if available, 60-95% alcohol) can also be used.
o Providing cleaning staff with adequate cleaning equipment, materials and disinfectant.
o Review general cleaning systems, training cleaning staff on appropriate cleaning
procedures and appropriate frequency in high use or high-risk areas.
o Where it is anticipated that cleaners will be required to clean areas that have been or are
suspected to have been contaminated with COVID-19, providing them with appropriate
PPE: gowns or aprons, gloves, eye protection (masks, goggles or face screens) and boots
or closed work shoes. If appropriate PPE is not available, cleaners should be provided with
best available alternatives.
o Training cleaners in proper hygiene (including handwashing) prior to, during and after
conducting cleaning activities; how to safely use PPE (where required); in waste control
(including for used PPE and cleaning materials).
The Project will take in in writing from the Concessionaire of the
o measures being taken to address the risks, presented as a contingency plan, as an

extension of the existing project emergency and preparedness plan or as standalone
procedures.
79
o Concessionaire to convene regular meetings with the project health and safety
specialists and medical staff (and where appropriate the local health authorities), and
to take their advice in designing and implementing the agreed measures.
o a senior person should be identified as a focal point to deal with COVID-19 issues
responsible for coordinating preparation of the site and making sure that the measures
taken are communicated to the workers, those entering the site and the local
community.
o The client may provide support to projects in identifying appropriate mitigation
measures, particularly where these will involve interface with local services, in
particular health and emergency services.
o The grievance redress mechanism set up for the project will have special number only
for reporting concerns relating to COVID-19. The number will be widely disseminated
and will also be put on the information board at all project sites.
Part 5 – Guidelines for staffing of a Core team of 3 people for implementation of the Concessionaire's
ESHS obligations as per Clause 8.6 of the Concession Agreement
Minimum Qualifying Requirement
S.No Key Position Total Work Experience in

. Experience Similar Works Minimum Education Qualification
(years) (years)
Health Expert B.E. /B. Tech or Equivalent with

1. & Safety 10 5 Specialization / additional
Specialist* qualification in EHS related field.
Environmental Masters degree in Environment

2. 10 5
Specialist * related field
Social Master’s degree in Social Work or

3. 10 5
Specialist* equivalent
* He/she should have worked as a sole expert for Urban Infrastructure projects. Experience in environment
/ safety / Social Risk Assessment, resettlement and rehabilitation and Management plans related to similar
project would be preferred.
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Part 6 – Minimum Requirements and Guidelines for the preparation of the Screening Report as per
Clause 7.2 (a) (ii) of the Concession Agreement
The extent of assessment required to identify and mitigate the impacts largely depends upon the
complexities of project activities. The scrutiny and screening will be based on a detailed Environment and
Social Screening exercise, summarized in the following Format:
Environment and Social information format for screening
Project Title:
Implementing agency:
Project cost:
Project components:
Project location (Area/ district)
Screening Criteria Assessment of Explanatory note
category (High/ for categorisation
low)
1 Is the project in an eco-sensitive area or adjoining an eco-
sensitive area? (Yes/No) If Yes, which is the area?
Elaborate impact accordingly.
2 Will the project create significant/ limited/ no social
impacts?
 Involuntary land taking resulting in loss of
income from agricultural land, plantation or other
existing land-use.
 Involuntary land taking resulting in relocation of
title holder or non-titleholder households.
 Any reduction of access to traditional and river
dependent communities (to river and areas where they
earn for their primary or substantial livelihood).
 Any displacement or adverse impact on tribal
settlement(s).
 Any specific gender issues.
3 Will the project create significant / limited / no
environmental impacts during the construction stage?
(Significant / limited / no impacts)
 Clearance of vegetation/ tree-cover
 Direct discharge of construction run-off,
improper storage and disposal of excavation spoils,
wastes and other construction materials adversely
affecting water quality and flow regimes.
 Flooding of adjacent areas
 Improper storage and handling of substances
leading to contamination of soil and water
 Elevated noise and dust emission
 Disruption to traffic movements
 Damage to existing infrastructure, public
utilities, amenities etc.
 Failure to restore temporary construction sites
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 Possible conflicts with and/or disruption to local
community
 Health risks due to unhygienic conditions at
workers’ camps
 Safety hazards during construction
4 Will the project create significant / limited / no
environmental impacts during the operational stage?
(Significant / limited / no impacts)
 Flooding of adjacent areas
 Impacts to water quality due to effluent discharge
 Gas emissions
 Safety hazards
5 Do projects of this nature / type require prior
environmental clearance either from the MOEF&CC or
from a relevant state Government department?
(MOEF&CC/ relevant State Government department/ No
clearance at all)
6 Does the project involve any prior clearance from the
MOEF&CC or State Forest department for either the
conversion of forest land or for tree-cutting? (Yes/ No).
If yes, which?
7 Please attach photographs and location maps along with
this completed Environmental Information Format For
Screening.
Overall assessment
*Detailed explanation/ justification for arriving at specific category (high/ low) to be provided in the
specified column
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Schedule 9: Key Performance Indicators
1. Availability
The Concessionaire shall ensure that the Availability of the Facilities and the Associated
Infrastructure on every day during the O&M Period shall be 100% (the “Guaranteed Availability”).
2. Treated Effluent Quality

The Treated Effluent shall meet the following requirements.
Parameter Unit Value for STP
pH 5.5-9.0
BOD mg/L ≤10
TSS mg/L ≤20
COD mg/L ≤50
Nitrogen Total mg/L ≤10
Phosphorus Total mg/L ≤1.0
Faecal Coliform MPN/100 mL ≤230
The Concessionaire shall not be responsible for adherence to the above requirements of Treated
Effluent in an event the values of the Influent Standards are as per table below.
Item/ Parameter/
Units Value for STP
Description
pH 6.0-8.5
BOD mg/L >250
TSS mg/L >500
COD mg/L >500
Nitrogen Total mg/L 50
Phosphorus Total mg/L 9
3. Digested/dewatered sludge
The digested sludge shall meet the minimum standards as per USEPA part 503 (US-EPA, 1992) as
follows:
Units Value
Outlet Concentration of More than 20% solids
dewatered sludge
Faecal coliform 1000 MPN / g
Salmonella 3 MPN/4 g
Viruses 1 FPU/4 g
helminth egg 1 helminth egg/4 g
4. Biogas Production
83
Minimum quantity of biogas to be generated and made available to the CBG facility – 70 Nm3 per
MLD]3.
Should there be a 25% reduction in flow and / or suspended solids, volatile suspended solids and
BOD, the concessionaire will not be liable to meet the minimum biogas yield.
5. Energy guarantee
The concessionaire shall guarantee the maximum number of units of power per MLD of treated
sewage. To operate and maintain the Facilities including STP, pump houses and other associated
Infrastructure (at varying volumes and BOD of sewage), the actual power consumed at the STP/SPS
during the O&M period (other than any units expected to be generated and consumed from any
power plant proposed to be set up by the Concessionaire) should be less than or equivalent to the
quoted guaranteed power units for the respective STP/SPS, (Refer clause 9.4 (g) (C) of CA).
6. Assessment of compliance to KPIs

The assessment of compliance to KPIs for each of the parameters shall be checked in accordance
with the reports from online monitoring system and/or laboratory tests as set out above in point no.
2. Each parameter at STP constructed by concessionaire shall be checked. (Refer clause 8.12 of
CA)
3
Failure to meet the minimum quantity of biogas generation, for reasons that are attributable to Concessionaire, will
be considered as Concessionaire Event of Default, in accordance with clause 16.1 of the Concession Agreement.
84
Schedule 10: Technical Specifications
Contents
Part Section Title
A Process requirements and design criteria of sewage work
B Technical specifications
G1 General requirement
G2 Materials and workmanship
G3 General civil specifications
G4.1 General Mechanical Specifications
G5.1 General Electrical Specifications
G5.2 Technical specification for Diesel generator set
G5.3 Erection, testing and commissioning
G5.4 Instrumentation works
G5.5 SCADA (Online Monitoring System) for STP and LS/ PS
G5.6 Inspection and testing at manufacturer’s works
C Testing and Commissioning
D Specifications for Operation and Maintenance
E Electrical load list
85
PART A - PROCESS REQUIREMENTS AND DESIGN CRITERIA OF SEWERAGE WORK
86
PART A - PROCESS REQUIREMENTS AND DESIGN CRITERIA OF SEWERAGE WORK
All parts of Schedule 10 relate to the proposed centralized STP of Saharanpur.
The concessionaire shall submit the design and method statement for execution of any works prior to start
execution and get it approved by PE, UPJN.
1. Flows and raw Sewage characteristics
The process requirements stated in this section are to be read in conjunction with Schedule 1 Scope
of Work for the names of STP.
The Influent characteristics for Saharanpur STP are stated below: -
Name of STP Units Value for Saharanpur STP
Design capacity for sewage MLD 135

(Average)
Design capacity of septage to be co- KLD 50

treated at Saharanpur
Parameter/ Description Units Values for Saharanpur STP

pH - 6.0-8.5
BOD5 at 20°C mg/L ≤250
COD mg/L ≤500
TSS mg/L ≤500
Phosphrus mg/L 9
Nitreogen mg/L 50
KjelddahlN mg/L 45
Note: Influent standards provided above is the influent sewage characteristic. In addition to the above,
Concessionaire to assess and consider the quality and quantity of input sewage characteristic based on
sewage treatment plant configuration adopted for co-treatment of 50KLD of septage.
The concessionaire must make sure that the treated effluent and digested sludge meet the disposal
standards as mentioned in the KPI.Refer to the table provided in point no.2 of schedule 9.
2. General design requirements
87
The Concessionaire shall design the Facilities in accordance with the provisions of the IS codes,
Central Public Health and Environmental Engineering Organisation (CPHEEO) manual on
Sewerage and Sewage Treatment, Good Industry Practices and Applicable Laws.
The precedence for process and hydraulics shall be CPHEEO manual followed by the IS codes and
Good Industry Practices. The precedence for civil, structural, mechanical & electrical processes
shall be IS Codes followed by CPHEEO manual and Good Industry Practices.
The STP shall be designed by the Concessionaire to receive and treat all combinations of Sewage
influent flows and loads in accordance with the Influent Standards specified above.
Concessionaire's plant design shall fully comply with the minimum requirements specified in this
schedule and other schedules, regardless of whether or not such requirements or any related
components are shown in any drawings included or document issued by the Employer.
All interconnecting channels, launders, pipe line shall be designed for peak flows.
2.1. Design life
The Facilities shall be designed and constructed to provide the minimum service life as prescribed
in CPHEEO guidelines (2013) Chapter-2 Table 2.1 Design period of sewerage components.
2.2. Per Capita Water Supply and Sewage Generation
Per Capita water supply and Sewerage Generation shall be considered as per CPHEEO Sewerage
manual.
2.3. Infiltration
Estimate of flow in sanitary sewers have to include flows due to infiltration of ground water. In
light of general geological structure, ground water occurrence and topography, the ground water
infiltration is considered for the proposed networks. For the design purpose, infiltration is
considered as 10%.
2.4. Peak factors
The peak factor shall be considered as per CPHEEO guidelines (2013)

Contributory Population Peak Factor
Up to 20000 3.00
20001 to 50000 2.50
50001 to 75000 2.25
Above 75001 2.00
88
2.5. Design flows
Design flows are essentially peak dry weather flows. Peak dry weather flows would comprise of
peak domestic sewage flow plus infiltration as per below.
SectionalAverage CumulativeAverage CumulativeIn

Pipe Peakflow
flow flow filtration
(a) (b) (c) (d) (e)
= Sectional =SectionalSewageAverag = =(c) xPeakFactor+ (d)
populationxsewage eflow+cumulativeaverage 10%ofCumula =CumulativeSewageAver
(watersupplyratex flowfrompreviousconne tiveSewageA ageflowx
returnfactor) cting node(s) verageflow PeakFactor+Cumulative
Infiltration
2.6. IS codes for Sewerage System
Proposed sewerage system shall generally conform to the following publications of the Indian
Standards Institution and applicable Indian standards:
IS: 458 Precast Concrete Pipes (With and Without Reinforcement) – Specification
IS: 14333 High density polyethylene pipe for sewerage
IS: 15328 Un-plasticised Non-Pressure Polyvinyl Chloride (PVC-U) Pipes for use in
Underground Drainage and Sewerage Systems
IS: 783 Code of Practice for Laying of Concrete Pipes
IS:4111 (Part 1) Code of Practice for Ancillary Structures in Sewerage System: Part 1 Manholes
IS:4111 (Part 4) Code of Practice for Ancillary Structures in Sewerage system: Part 4 Pumping
stations and pumping mains (rising mains)
IS: 5455 Specification for Cast Iron Steps for Manholes
IS: 10151 Polyvinyl Chloride (PVC) and its Copolymers for its Safe Use in Contact with
Foodstuffs, Pharmaceuticals and Drinking Water
IS: 6280 Specification for Sewage Screens
IS: 5600 Pumps-Sewage and Drainage
IS: 8329 Centrifugally Cast (Spun) Ductile Iron Pressure Pipes for Water, Gas and Sewage
Specification``
IS: 11972 Code of practice for safety precautions to be taken when entering a sewerage
System
IS: 12592 Precast Concrete Manhole Cover And Frame — Specification
IS: 13496 General Requirements of Suction Machine for Cleaning Sewers, Manholes and
Ancillary Structures Provided On Sewer Line and Closed Storm Water Drains
IRC: 6 Standard Specifications and Code of Practice for Road Bridges – Section II – Loads
and Stresses
2.7. Design parameters for gravity collection system
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2.7.1. Design formula(As per CPHEEO)
Manning’s formula is adopted for design of gravity sewers.
Qf = A x Vf
Vf = 1/N x R2/3 x S1/2
Where,
Qf = Flow rate when pipe flows full in cumecs
Vf = Velocity when pipe flows full in mps
2.7.2. Coefficient of Roughness
For sewers with diameters within range of 150-1400mm, RCC pipes with S&S joints have been
proposed where Manning’s coefficient ‘n’ is considered as 0.011. For HDPE pipes manning’s
coefficient ‘n’ is considered as 0.011. For design purpose, n/N is considered as constant.
2.7.3. Pipe Material for Gravity Sewers
RCC NP3 class pipes conforming to IS: 458 with Sulphate Resistant Cement and rubber ring joints
shall be proposed. For highway crossings and pipe jacking, RCC NP4 pipes are proposed.
2.7.4. Design Capacity of Sewers
Sewers are designed to carry estimated peak flows generated in the design year. As far as possible,
they will be designed to run maximum 80% full at ultimate peak flow as per the CPHEEO Manual.
This is to ensure proper ventilation and to prevent the sewage getting septic.
2.7.5. Self Cleansing Velocities
To ensure that deposition of suspended solids does not take place, self-cleansing velocities using
Shield’s formula will be considered in the design of sewers.
V= (1/n) x R1/6 {KS (SS – 1) x dp}1/2
KS = Dimensionless constant @ 0.04 to start motion of granular particle and @ 0.8 for
adequate self cleansing velocity.
SS = Specific Gravity of Particle
dp = Particle size
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The above formula indicates that velocity required to transport material in sewers is mainly
dependent on the particle size and specific gravity and only slightly dependent on conduit shape
and depth of flow.
The sewers are designed on the assumption that although silting might occur at minimum flow, it
would be flushed out during peak flows. Erosion of sewers is caused by sand and other gritty
material in the sewer and also by excessive velocity.
Based on above, the velocity criteria which is considered is as given below.
Minimum velocity = 0.80 m/s

Maximum velocity = 3.00 m/s
An attempt shall be made to obtain adequate self cleansing velocities in the design of sanitary sewer
at the average or at least at the maximum flow at the beginning of the design period. If the velocity
criteria do not meet for initial stretches of sewers due to less flow, these stretches will need to be
flushed at regular intervals to avoid clogging of sewers.
2.7.6. Minimum size and gradient of sewers
The gradients adopted for the sewers shall be in concurrence with the CPHEEO manual. The
gradients adopted for the sewers shall be based on flow and velocity requirements. The crown levels
of incoming and outgoing sewers shall be kept same.Whenever required drop manholes shall be
provided.
2.7.7. Depth of cover
Minimum depth of cover
To facilitate house sewer connections and future laterals connections to the street manholes and to
provide sewer protection from external loads, the minimum depth of cover is considered as 1 m.
2.8. Design parameters for rising mains / pressure pipes (As per CPHEEO)
For Pressure pipe, Hazen William formula is adopted V= 0.85 x C x R 0.63 x S 0.54
for circular conduits, the expression becomes
V = 4 .567 x 10 - 3 C D 0.63 S 0.54

where,
Q : Discharge in m3/hr
D : Internal diameter of pipe in mm
V : Velocity in m/s
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R : Hydraulic radius in m
S : Slope of hydraulic gradient and
C : Hazen - Williams coefficient as in Table 3.14 (CPHEEO Manual)
For Rising Mains, Ductile Iron (DI) of Class K9 pipes with internally smooth cement mortar lining
are proposed.
Minimum velocity = 0.80 m/s

Maximum velocity = 3.00 m/s
Losses in fitting shall be computed as per latest CPHEEO Manual.
2.9. Bedding for sewers
The type of bedding (Granular Bedding, Plain Cement Concrete Cradle Bedding, Reinforced
Cement Concrete Cradle Bedding and Reinforced Cement Concrete Encasement) depends on the
weight of soil above the pipe based on width of trench, depth at which the sewer pipe is laid and
the class of superimposed vehicular load considered based on the traffic condition.
For RCC (NP3 class) pipes, the appropriate bedding shall be provided based on the bedding factor
calculated considering load due to backfill, the superimposed (live) load and the three edge bearing
strength of RCC pipes as per IS:458.
The bedding factor is calculated by following formula.
Bedding Factor = Total Load (kN/m) x Factor of Safety

Three Edge Bearing Strength (kN/m)
Where, Total load is sum of Earth load, Vehicular load and Water load
Three Edge Bearing Strength of RCC pipe is considered as per IS: 458
Factor of safety is considered as 1.5.
Impact factor for vehicular traffic depends on cover above top of pipes. For sewers, the depth of
cover is more than 900mm, hence impact factor is considered as 1.0 as per IS:783.
The type of bedding to be used, depending on the bedding factor shall be as indicated.
Bedding factor Type of bedding Class of bedding

Up to 1.9 Granular Bedding with Carefully Compacted B
Backfill (GRB)
For more than 1.9 and Concrete Cradle Bedding with Carefully Ab
upto 2.8 Compacted Backfill (PCCB)
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Bedding factor Type of bedding Class of bedding
For more than 2.8 and Reinforced concrete cradle with percentage of Ac
up to 3.4 reinforcement `p’ equal to 0.4% with carefully
compacted backfill (RCCB)
For more than 3.4 and Reinforced Concrete Encasement with Ad
up to 4.8 percentage of reinforcement `p’ equal to 1% (RCE)
(Note: ‘p’ is the ratio of the area of transverse reinforcement to the area of concrete cradle at the pipe
invert above the base)
2.10. Manholes
2.10.1. Ordinary manhole
Manholes are to be provided at all junctions, change of sewer size, gradient and direction. The sizes
of manholes adopted are in line with the recommendations of CPHEEO Manual for Sewerage and
Sewage treatment. In general, to facilitate the cleaning and maintenance the Manhole spacing is
kept as per CPHEEO Manual.
The clear opening at the top in case of ordinary manholes is kept as 560 mm. The manhole frame
and cover is proposed of Steel Fiber Reinforced Concrete (SFRC) capable of withstanding heavy-
duty loads (HD-20 for side lanes), (HD-35 for main roads) conforming to IS: 12592-2002.
The street manholes will be circular in shape with concentric cone depending on the depth and
diameter of sewers. Based on the sewer diameters CPHEEO Manual for Sewerage and sewage
treatment recommends the internal diameter of the manhole should not be less than internal
diameter of largest sewer plus 150mm of benching on both sides. However, from practical
considerations the benching width for sewer diameter greater than 450mm is kept as 300mm on
both sides. The internal diameters of manholes for varying depths as recommended by CPHEEO
Manual for Sewerage and sewage treatment will be as follows.
Description Dimension
For depths above 0.90m and up to 1.65m 900mm diameter
It is desirable to place the first pipe joint (S/S) outside the manhole as close as practicable. This
pipe shall be built inside the wall of the manhole flush with the internal periphery protected with
an arch of masonry or cement concrete to prevent it from being crushed.
The inside and outside of brickwork should be plastered with cement mortar (1:3) inside finished
smooth with a coat of neat cement.
93
Due to availability of plenty of bricks locally and less cost, Brick Masonry manholes are proposed
wherein house connections / lateral sewers can be done conveniently. However, RCC manholes are
also considered for sub-soil water conditions. RCC manholes are considered as square for ease in
construction as the cost difference between circular and square type of RCC manholes are marginal.
Precast concrete manholes are also considered for congested and narrow lanes for speedy
construction for manhole depth upto 1.65m for pipes upto 400mm dia.
The type and size of manholes (depth-wise) is given below.
Type and size of manholes for proposed sewerage works

Type of Diameter of Size of Size of
Depth of manhole
manhole pipe manhole opening
BRICK
MASONRY
Rectangular
R2-Type For depth upto 2.5 m Upto 400 mm 1200 X 900mm 560mm dia.
Manhole
Circular
A-Type For depth 1.2 m and upto 1.65m Upto 400 mm 900 mm dia 560mm dia.
Manhole
B-Type For depth 1.66 m and upto 2.0 m Upto 600 mm 1200 mm dia 560mm dia.
Manhole
For depth 2.01 m and upto 2.3 m
C-Type For depth 2.31 m and upto 3.0 m Upto 900 mm 1500 mm dia 560mm dia.
Manhole
D-Type For depth 3.01 m and upto 4.5 m 1000 to 1200 1800 mm dia 560mm dia.
Manhole mm
Scraper
Manhole
S1-Type For depth upto 1.5 m 500 to 900mm 1500mm 2 nos. 900 x
Manhole X1500 mm 600mm
For depth 1.5 m and up to 3 m
For depth 3 m and up to 4.5 m
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Type of Diameter of Size of Size of
Depth of manhole
manhole pipe manhole opening
For depth 12 m and up to 14 m
S2-Type For depth upto 1.5 m 1000 to 1800mm X1500 2 nos. 900 x
Manhole 1200mm mm 600mm
For depth 1.5 m and upto 3 m

For depth 3 m and upto 4.5 m
For depth 12 m and upto 14 m
RCC
MANHOLE
S
Type-A For depth upto 1.5 m Upto 300mm 1500mm X1500 560mm dia.
Dia. mm
For depth 1.5 m and upto 3.0 m Upto 450mm
Dia.
Type-B For depth 3.0 m and upto 4.5 m Upto 600mm 1500mm X1500 560mm dia.
Dia. mm
For depth 4.5 m and upto 6.0 m Upto 900mm
Dia.
Type-C For depth 6.0 m and upto 7.5 m 1000- 1200mm 1800mm X1800 560mm dia.
Dia. mm
Type-D0 For depth 9.0 m and upto 10.5 m Above 2200mm X2200 560mm dia
1200mm Dia. mm
PRECAST CONCRETE MANHOLES
Type-E For depth 1.2 m and upto 1.65m Upto 400 mm 1000 mm dia 560mm dia.
2.10.2. Drop arrangement
Drop arrangement is proposed for the laterals joining the manholes of main sewer wherein level
between maximum water line (peak flow level) of main line and invert level of lateral/branch sewer
is greater than 600mm.
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3. Interception and Diversion of Nala
Interception and diversion of Nala shall be carried out as per the CPHEEO manual/ applicable
standards.The design shall include Nala/drain Catchment area estimation, Design flood discharge,
DWF, water way at weir, discharge per unit width, Head over weir, depth of cut-off and creep
length required.Mechanical & manual screens shall be provided at each I&Ds. Periodic removal of
trash and cleaning of screens need to be undertaken by the concessionaire during O&M period.
Actuator gates and flow measuring instrument need to be provided at I&Ds.
Necessary power arrangement including standby need to be provided at the I&Ds.
DWF shall be considered as per actual flow measurement to be carriedout by the concessionaire
for a minimum period 14 days at all Nalas/Drains. Peak flow shall be considered for the designing
of the I&Ds.
4. Sewage pumping station(SPS)
i. Sewage Pumping Stations are provided to lift sewage so as to discharge into another gravity
sewer or inlet chamber of treatment plant. Hydraulic criteria adopted in the design of
Sewage Pumping Station will be follows:-
a) Peak Factors ranging from 2 to 3 are considered for design peak flows.
b) Velocity in pumping main range from 0.8 m/sec (minimum) to 3 m/sec (maximum).
c) Wet well volume is generally computed based on the pump capacity & no. of starts and
stops per hour as given below. Also it is calculated based on 3.75 minutes detention time
at peak flow as per NRCD Guidelines.
Wet Well volume, V=0.25* Q / N (Considering design year flows)
Where Q – pumping rate in cum/hr of largest pump installed for parallel arrangement.
N- No. of starts & stops per hour considering manual start/stop also.
d) Velocity through the screen is 0.9 m/sec at peak flow.
e) Hazen William`s Coefficient will be considered as 140 for DI pipe.
f) Minimum residual head is considered as 2 m for pump head design.
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g) The Pumps, Electro-Mechanical Units and other related accessories are designed
considering present and.flows up to 2035.
ii. The selection of pumps , pumping main size, Electro-Mechanical Units design shall be
based on the following criteria besides head & discharge requirements.
a) Submersible non clog pumps may be considered for medium/small PS (<= 50

MLD), whereas horizontal type non-clog centrifugal pumps with positive suction
pumps as appropriate are proposed for large pumping station (>= 50 MLD).
b) The pumps shall have single speed with low rpm (less than 1000 rpm except for
MPS where it will be less than 750 rpm) & as far as possible, of equal capacities.
c) The pump configurations will be selected as per NRCD/MoEF Guidelines as given

in following table.
Length of Rising Main Pumps No. of Pumps

Where rising main is long Peak Flow/2 3 nos. (including 1
and where head losses are pumps standby)
the dominant factor Non Peak Flow 2 nos. (including 1
pumps standby)
Where rising main is short Peak Flow/4 6 nos. (including 2
and static head is dominant pumps standby)
d) In case the rising mains are long, head losses are dominant factor, in case the rising
mains length is short, static head is dominant factor.
e) Depending on present & future flows (minimum, average and peak) suitable
capacity of pumps will be selected.
f) For small sewage pumping stations upto 15.00MLD, equal duty pumps of half peak
flow with the provision of 100% standby peak flow shall be considered.
g) For medium & large pumping stations above 15.00MLD capacity, equal duty
pumps of 1/4th of peak flow with 50% standby and 50% spare shall be provided.
10% additional capacity for pumps shall be considered. Parallel operation of more
than four number of pumps shall be avoided. A/C deficiency (losses) due to parallel
operation of pump shall be minimized.
h) For pumping station, provision should be made for automatic start & stop, the
system would be capable of being operated manually.
i) A maximum of two starts & two stops per hour should be considered for manual
operations of the pump. A higher no. of starts & stops shall be considered for the
automatic operation.
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j) Pump shall have non clog semi open impeller and preferably having not more than
two vanes.
k) MOC of pumps shall be as per mentioned below ,
Casing Cast Iron as IS 210 Grade F260 with Ni 2%
Impeller Submersible pumps- Stain less Steel (CF 8M) / preferably

duplex stainless steel CD3MCuN(minimum 24%
chromium, carbon<0.03%) with good hardness 220-260
BHN,
Dry well Horizontal centrifugal pumps- duplex stainless
steel CD3MCuN(minimum 24% chromium,
carbon<0.03%) with good hardness 220-260 BHN
Shaft AISI 410
Wear ring /Neck duplex stainless steel CD3MCuN (minimum 24%

ring chromium, carbon<0.03%) with hardness 50 BHN lesser
than that of impeller
l) HT motors for more than 250 kW rating shall be considered. The incoming power
supply for these pumps shall be preferable at 3.3/6.6kV
m) Motor H.P rating shall be considered with additional margin over BKW at duty
point as per section 11.1.9 latest CPHEEO Manual.
n) Mechanically operated Stainless steel screens for SPS would be provided ahead of
the wet well to prevent large size solids entering the pump. Selection of rack shall
vary on depth. Drum type screens shall be avoided. Rectangular screen to be
installed on approx. maximum 60° angle from Horizontal for Manual Screen &
maximum 80° angle from Horizontal for Mechanical Screen. Motors provided for
screens, clarifiers, Detroiters shall have sufficient margin for overloading due to
foreign materials such as jutes, plastics, nylon ropes etc.
o) All the sluice gates in the SPS area will be made from Cast Iron –Flush bottom
Rising Spindle type.
p) Natural or forced ventilation system would be provided for deep pumping station,
with dry-wet well configuration and screen chambers.
q) Level indicators would be provided for SPS.
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r) Overhead travelling cranes of capacity as required shall be electrically operated.
Also adequate loading platform shall be provided for material handling.Also,
adequate loading platform shall be provided for material handling.
s) The material for rising main is considered as Ductile Iron as per IS: 8239:2000.
t) Shut off head of pumps should be minimum 20-30% higher than duty point head.
Electrically operated overhead travelling cranes of adequate capacity shall be provided. Also, adequate
loading platform shall be provided for material handling.
5. Process requirements of STP
The following main treatment processes and requirements must be provided:

 Preliminary treatment (screenings & grit removal)
 Secondary biological treatment
 Sludge digestion
 Sludge thickening, dewatering & storage
 [Any other facilities as required for co-treatment of septage ]4
 Transportation of Screenings, Residual Grit and Digested Sludge from the Facilities and
Associated Infrastructure to the Waste Disposal Site.
 Disinfection system
Nitrogen and Phosphorus Removal Process

Concessionaire can propose any proven treatment process for nitrogen and phosphorus removal
(also collectively referred to as “nutrient removal”), provided that they are designed to achieve the
Key Performance Indicators as specified in Schedule 9 to the Concession Agreement along with
meeting the requirement of power generation wherever applicable. The nutrient removal treatment
system shall be designed for average flow including recirculation and other flows (Co -Treatment
of septage), if any. The designs submitted by the concessionaire for STP under the Project will be
reviewed in-depth to give reasonable assurance that it shall strictly adhere to the above
requirements. Further, during operation the concessionaire shall ensure to maintain the required
process protocols to meet the Key Performance Indicators, which will be enforced on a real time
basis using the data provided by the water quality monitoring instruments to be installed at inlet
and outlet of each STP, consistent with the provisions of Section G5.4: Instrumentation Works.
4
If Co-treatment of faecal sludge is proposed.
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6. Description of process and facilities
This section outlines the major processes and Facilities that the Concessionaire is required to
design, construct, and operate as per this Concession Agreement.
6.1. Stilling chamber
A stilling chamber shall be provided at the inlet of STP to receive the raw Sewage from the pumping
station. The stilling chamber shall reduce the turbulence of raw water entering into it. The stilling
chamber should be kept clean by removing silt, sand deposited and the algae growth at the bottom
andsides.
6.2. Fine screens
The raw Sewage from rising main shall flow to fine screen inlet channel by gravity. The mechanical
fine screen shall be either bar/perforated screen. The screens shall have clear openings not
exceeding 6 mm. The screens shall be equipped with an automatic cleaning system and can be
controlled by both an adjustable timed cycle and a pre-set differential head across the screen using
ultrasonic level sensors. All screens shall be provided with thimble mounted isolation sluice
gates(actuator operated with manual override) both on upstream and downstream. The
Concessionaire should provide bypass channel with manual screen considering the overall
screening capacity shall be 100% peak flow with one screen out of service.
6.3. Grit basins with Grit washers and classifiers
The Concessionaire shall provide Grit separators downstream of the screens. The grit removal
device shall be capable of removing the following at the specified hydraulic peak flow rate, and no
decrease in efficiency will be allowed at flows less than this design rate.
- 95% of the grit greater than 150 microns in size,
- 90% of the grit greater than 100 but less than 150 microns in size.
A Parshall Flume shall be provided downstream of Grit separators.. The flow measurement shall
be instantaneous and capable to transmit the data automatically to SCADA
6.4. Primary clarifiers
If proposed, the primary clarifiers with scum removal shall be designed as per CPHEEO manual.
6.5. Aeration systems
The aeration system shall be designed to maximise oxygen transfer and to adapt to the changing
oxygen demands in biological treatment systems. The aeration system shall be capable of complete
and uniform mixing and suspension of mixed liquor suspended solids.
6.6. Disinfection
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Disinfection shall be provided to comply with KPIs as required by the Concession Agreement,
through chlorination systems or UV disinfection or ozonation. The Concessionaire shall ensure that
disinfectants used shall not exceed the limits as per the provisions of the Environment (Protection)
Rules, 1986. Such excess disinfectant levels, if any, need to be neutralized before disposal to inland
surface water or land for irrigation.
6.7. Sludge Thickeners
The sludge thickeners may be either gravity thickeners or mechanical thickeners. All associated
ancillaries such as all pumps and polymer dosing equipment shall be arranged. Required standby
arrangement shall beprovided.
6.8. Sludge digestion
The design of the sludge digestion system shall ensure that maintenance of all equipment and
components can be safely and easily accomplished from outside the digester and without draining
its contents.
If anaerobic digestion is proposed, the Concessionaire shall provide gas holders and gas burners. If
provided, the sludge heating system may be complete with heat exchangers, sludge re-circulation
pumps, hot water pumps. The heat requirement of digesters during winter season will be met
through the heat available from bio gas engine and additional requirement to be fulfil through
boiler, if required.
The Concessionaire shall ensure safety and security of operation as the result of the presence of
biogas in both normal and abnormal operation.
6.9. Dewatering system
Digested Sludge shall be mechanically dewatered to produce a cake concentration of at least 20%
dry solids and the solids recovery shall not be less than 95%. The dewatering facility and associated
ancillaries such as all pumps and polymer dosing equipment shall be arranged in at least two parallel
streams (1 working + 1 standby), each sized to handle the average daily sludge quantities over not
more than 16 hours perday. The dewatered sludge shall be disposed off .
The concessionaire shall ensure at least 38% of reduction of Volatile solids for Vector Attraction
Reduction during sludge treatment. The Concessionaire shall also ensure less than 20,00,000 most
probable number per gram of total dry solids (20,00,000 MPN/gTS) in sludge before disposal.
6.10. Facilities drain sump and pump station
A drain pump station shall be provided to collect recyclables such as filtrates from
thickener/dewatering units and other miscellaneous waste flows such as sewage generated from
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Facilities, cleaning and wash-down flows and pump them back up to the inlet chamber of the
Facilities.
6.11. Treated Effluent disposal pipe line
A Treated Effluent disposal pipe line shall be provided to discharge the effluent to the Discharge
Point either by gravity or by pumping as per site codition. Outfall of treated discharge in River
should be with some architectural feature, for example- waterfall in staircase or stone form etc.
6.12. Co-Treatment of septage in the Proposed 135 MLD STP

Process involved in co-treatment of septage in the sewage treatment plant shall be as per CPHEEO
Manual. The facilities shall be designed with adequate capacity to accept the septage without
hampering the functioning of the sewage treatment plant. Sludge from septage and sludge from
sewage shall be treated separately to achieve the relevant KPIs mentioned in Schedule-9.
The Filtrate /Centrate /Supernatant from the Septage shall be treated in the Liquid stream of STP.
Increase in hydraulic and influent characteristic due addition of Filtrate /Centrate /Supernatant in
liquid stream of STP should be considered in designing of facilities.
6.13 Sludge drying and storage

At STP, sludge drying system shall be provided along with a temporary storage facility for stacking
of the dried sludge. The temporary storage area shall have minimum capacity for storing dried
sludge generated for Four weeks.
7. Facilities within STP
7.1. Energy generation
At Saharanpur STP
The Concessionaire shall generate biogas produced by the sludge digestion process and create
necessary infrastructure to convey the same to a designated supply point within the premises.
The design and specification of the units shall take into account the contaminants that will be
present in the biogas from the digesters, such as hydrogen sulphide (H2S) and ammonia (NH3), and
any harmful effects resulting from their combustion. The Concessionaire shall provide a H2S gas
scrubbing system, to protect the engine and maintain its design life.
7.2. Gas holders
The gas holders shall as per CPHEEO manual. A flame arrestor and flow meter shall be provided
on the gas line from each digester. The gas storage system shall be equipped with storage capacity
of at least 100% of the total daily gas production
7.3. Biogas burner
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The bio gas burner (if provided) shall be designed as per CPHEEO manual and should be provided
in 2 numbers (1working +1 standby) for complete destruction of all contaminants in the gas. All
gas pipework and weld on flanges shall be stainless steel 316L.
8. Flood protection:
The Finshed ground level (FGL) of the Facilities to be at or above the High flood level. Building
plinth, top of wet wells , I&Ds ,and other structures shall be at 0.45 m above HFL.
SOIL EROSION CONTROL MEASURES AT PROPOSED STP SITE

The FGL of proposed STP site needs to be fixed keeping in view the HFL of rivers flowing nearby
around. The NGL of STP site is lower than the HFL of Paondhoi and Dhamola rivers and therefore
earth filling is required to be carried out so that FGL of STP site can be fixed appropriately and
suiting the site conditions.
Filling at the STP site will lead to change in the topography as the area where STP is proposed shall
be raised. The soil slopes of the raised STP site shall be protected by compacting the soil to 95%
Dry Density followed by laying of filter media (coarse sand / gravel or any approved material) to
prevent escape of soil material from the slopes. The gradation of the filter media shall satisfy the
requirements of IS or MoRTH. The stone pitching shall commence in a trench below the toe of the
soil slopes and raised upwards along the slope line. The pattern of laying the pitching stones shall
be such that the joints are broken and voids are minimum by packing the spall wherever is necessary
and top surface is as smooth as possible. Any voids visible should be filled with Cement sand slurry
(flowing type) of 1: 6.
Stone pitching on the slopes Riprap wall
Further, all around the STP site and immediately at the start of the toe of the land fill slope,
layer the rocks so the riprap is 12 to 18 inches (0.30 to 0.46 m) thick. Place the largest rocks as
the bottom layer. Fill in the areas between them with smaller stones. Make the rocks fit together
as close as possible so water cannot move around or through them. Use a variety of stone sizes
to fill in the space as much as possible. Alternatively, Gabions can be laid.
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PART-B
TECHNICAL SPECIFICATIONS
104
Section G1: General requirements
1. ExecutingAgency’s drawings
The drawings listed in the Tender Document are the Executing Agency’s drawings and are provided
by the Executing Agency as illustrative of the Specification.
All data and information furnished in the drawings by the Executing Agency is given in good faith
but the Executing Agency does not accept the responsibility for the completeness and accuracy
thereof. The same shall be verified by the Concessionaire promptly pointing out errors or
discrepancies thereof to the Executing Agency.
2. Drawing sheet format
All drawings provided by the Concessionaire shall be on standard size sheets, in the form of black
or blue lines on a white background and shall show the following particulars in a title block located
in the lower right hand corner, in addition to the name of Concessionaire and equipment
manufacturer, date, scale, drawing number, revision number (RO for drawings submitted initially,
R1, R2. etc. for drawings submitted subsequently)
A blank space of 90 mm x 100 mm shall be provided for the Executing Agency’s approval stamp
and provision shall be made for details of revisions to be recorded.
All drawings submitted by the Concessionaire shall use the English language and preferably SI
units. All drawings shall be clearly and fully cross referenced to the other drawings as relevant.
3. Operation and maintenance manuals
The operation and maintenance manuals shall be arranged to provide separate volumes for each
principal section of the Works and they shall relate to a “As-built” conditions and shall include all
necessary drawings and diagrams for a proper understanding of the works.
The operation and maintenance manual shall be approved and shall cover all items of the Works.
For this purpose, three draft copies shall be submitted to the Executing Agency. A mere collection
of manufacturers’ descriptive leaflets will not be acceptable in satisfaction of this Clause. The
operation & maintenance manual shall comprise both operating instructions and maintenance
instructions and final O&M manual should be submitted by concessionaire 30 days prior to
COD of STP.
The Final O&M manuals shall include, but not be limited to the following information:
(a) Descriptive overview of the whole of the works.
105
(b) Descriptions of all systems installed, including mechanical, electrical, instrumentation,
control systems with relevant design and operating parameters.
(c) Descriptions of all equipment supplied including manufacturer’s leaflets, which shall be
scheduled for easy reference.
(d) Schedules and manufacturer’s catalogues for all equipment supplied, giving duties,
electrical load, etc.
(e) Schedules of all equipment suppliers (and their local agents) including names, addresses,
telephone, fax and e-mail numbers.
(f) Start-up, operation and shutdown instruction for all parts of the Works. These shall include
step-by-step directions on setting the Plant to work listing all adjustments and settings
necessary for the current functioning of the Plant.
(g) Instructions on monitoring of Plant performance and sample log sheets for each Plant item,
to be filled by operators on a routine basis.
(h) “Dos” and “Don’ts” in Plant operation. Operator’s attention shall be drawn to all operations
considered dangerous to operators or likely to cause damage to the Plant.
(i) Procedures to deal with breakdown and emergencies.
(j) Safety requirements.
(k) Checking, testing and replacement procedures to be carried out on all Plant items on a
daily, weekly and monthly basis or at longer intervals to ensure trouble free operation. Full
maintenance instructions for all equipment including planned maintenance schedules or
charts giving daily, weekly, monthly, quarterly, half yearly annually and overall
instructions, together with recommended lubricants and spares. These shall also include
details of routine maintenance work that will be within the competence of the normal
maintenance staff and notification of maintenance work that will have to be done by the
manufacturer, his agent or other specialist operator.
(l) Fault locations and remedy charts to facilitate tracing the cause of malfunctions or
breakdown and correcting faults.
(m) Complete list of recommended lubricants and lubrications charts.
(n) A “Spares Schedule”, which shall consist of a complete list of item wise spares for all Plant
items with ordering references and part numbers.
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(o) A complete list of manufacturer’s instructions for operation and maintenance of all bought
out equipment. The list shall be tabulated in alphabetical order, giving the name of supplier
/ manufacturer, identification of the Plant item, giving the model number and the literature
provided including instruction leaflets and drawing numbers.
(p) Step by step procedure for the dismantling, repair and re-assembly of all items of
equipment.
(q) Part-list and drawings or exploded diagrams for each item of Plant with construction
particulars, materials of construction, mating components, clearances and tolerances,
maximum wear permitted before replacements are to be done, etc.
(r) Record drawings of all systems installed, including general arrangements, conduit and
wiring trunking systems, wiring diagrams, control schematics and valve charts etc., to a
reduced scale.
(s) Certified suppliers’ drawings of all equipment supplied, which shall be scheduled for easy
reference.
(t) Site test reports for all mechanical, electrical and instrumentation systems. Site test process
reports for proving tests, commissioning reports, and supplier’s test certificates.
(u) Copies of performance curves.
Each volume shall be durable and permanently bound within a stiff binder of a design to be
approved by the Executing Agency.
4. Protection and Packing for Transportation
Before any machinery, equipment or Plant is dispatched from manufacturer’s works, it shall be
properly prepared and packed and the Concessionaire shall give the Executing Agency at least
fourteen (14) days’ notice that these preparations are to commence and shall be inspected and check
for quality assurance and quality control parameters by the Employer.
Prior to dispatch, the Plant shall be adequately protected by painting or by other approved means
for the whole period of transit, storage and erection, against corrosion and incidental damage,
including the effects of vermin, sunlight, rain, high temperatures and humid atmosphere. The
Concessionaire shall be responsible for the Plant being so packed and / or protected as to ensure
that it reached the Site intact and undamaged. The Plant shall be packed to withstand rough
handling in transit and all packages shall be suitable for storage including possible delays in transit.
The Concessionaire shall be deemed to have included in the schedule of prices for all materials and
packing cases necessary for the safe package, conveyance and delivery and storage of the Plant
with all protective and preservation measures.
107
Cases containing rubber rings, bolts and other small items shall not normally weigh more than 50
kg, gross per case. No one package or bundle shall contain items of Plant intended for incorporation
in more than one section of the Works. All items of Plant shall be clearly marked for identification
against the packing list.
Eyebolts, lifting hooks and brackets shall be provided for lifting the boxes, crates and packages.
Every crate or package shall contain a packing list in a waterproof envelope. A duplicate copy of
the packing list shall be sent by post to the Executing Agency at site. Consignments imported by
ocean freight shall be packed and preserved as stipulated above.
All crates, packages, etc. shall be clearly marked with a waterproof material to show the weight
and where the slings should be attached, and shall also have an indelible identification mark relating
them to the packing lists. Packing cases shall be non-returnable. Concessionaire shall have to clear
the site including packing material.
Electrical equipment shall be enclosed in sealed airtight package with hygroscopic material, before
being placed in packing cases on shock absorbent materials and secured by means of battens.
5. Delivery, Unloading and Storing at Site
The Concessionaire shall be responsible for checking all materials delivered to site and shall keep
the Executing Agency’s Representative fully informed of the state of deliveries. The
Concessionaire shall carry out, at his cost, all instructions of Executing Agency for proper
unloading, preservation, maintenance, storage and security of materials delivered to site until he
fulfills all his obligations under the Contract.
The Concessionaire shall erect and maintain on the site any temporary storage facility as required
and approved by the Executing Agency. If built up shed or area is provided by the Executing
Agency depending upon availability, the Concessionaire shall have to pay rent as finalised by the
Executing Agency.
Multiple handling and movement of materials during storage and retrieval shall be avoided.
6. Spare Parts
Spares during pre-commissioning trials, commissioning tests / maintenance, guarantee etc. shall be
provided by the Concessionaire. The spares also include the consumables such as bulbs, fuses,
wires, lubricating oil, gaskets, packing seals etc. The necessary spares shall be brought by the
Concessionaire prior to the pre-commissioning test so as to avoid the downtime of equipment due
to non-availability of them. All the spares have to be provided as required, by Concessionaire free
of cost.
108
All spare parts shall be new, unused and strictly interchangeable with the parts for which they are
intended to be replacements and shall be treated and packed for long storage under the climatic
conditions prevailing at the site. Each spare part shall be clearly marked or labelled on the outside
of its packing with its description, number and purpose. When more than one spare is packed in a
single case or other container, a general description of its contents shall be shown on the outside of
such case or container and a detailed list enclosed. All cases, containers and other packages shall
be marked and numbered in an approved manner for the purpose of identification. Spares shall be
delivered to site after the completion of erection but before start of commissioning of Plant along
with technical leaflets and details. Spare parts shall be indicated in the assembly drawing showing
clearly the part numbers.
All cases, containers or other packages are liable to be opened for such examination as the
Executing Agency may require and packing shall be designed to facilitate opening and thereafter
repacking. In the event of the some specific spares offered in the Contract being withdrawn from
manufacture owing to changes in design of equipment or similar reasons viz., model being obsolete
etc., the Concessionaire shall inform the Executing Agency before such withdrawal, so that the
Executing Agency can take timely alternative steps.
7. Tools
Tools shall be delivered to site just prior to Tests on Completion.
The specified tools shall not be used for the erection of the Plant being supplied and except that the
Executing Agency may call upon the Concessionaire to demonstrate their use or effectiveness, they
must be handed over to the Employer in a completely new and unused condition. Should the
Concessionaire require any such tools at site for erection, he shall provide his own.
The test equipment shall include special purpose items essential to the testing or recalibration of
related items of Facilities.
8. Works to be kept clear of water
The Concessionaire shall keep the Works well drained until the Executing Agency certifies that the
whole of the Works is substantially complete and shall ensure that so far as is practicable, work is
carried out in the dry condition. Excavated areas shall be kept well drained and free from standing
water.
Notwithstanding any approval by the Executing Agency of the Concessionaire’s arrangements for
the exclusion of water, the Concessionaire shall be responsible for the sufficiency thereof and for
keeping the Works safe at all times, particularly during any floods and for making good at his own
expense any damage to the Works, including any that may be attributable to floods. Any loss of
production or additional costs of any kind that may result from floods shall be at the
Concessionaire’s own risk.
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9. Assistance for the Engineer’s Staff
The Concessionaire shall provide all necessary assistance to the Executing Agency and his staff in
carrying out their duties of checking the setting out, inspecting and measuring the Works. The
Concessionaire shall provide staff men, office attendants and labourers, as may be needed, from
time to time by the Executing Agency.
The Concessionaire shall provide for the Executing Agency and his staff such protective clothing,
safety helmets and rubber boots of suitable sizes, hand lamps and the like, as may reasonably be
required by them. These articles shall remain the property of the Concessionaire. No separate
payment shall be made on this account.
10. Internal Road Specifications:

Internal Road of 3.75 m width with following specifications:
40 mm thick bituminous concrete
50 mm thick bituminous Macadam
150 mm thick WMM
100 mm GSB
500 mm thick approved soil compacted
1 m wide berm both sides of interlocking tiles.
Maintenance to be carried out according to UPPWD norms.
110
Section G2
Materials and workmanship
111
Section G2: Materials and Workmanship
1. Introduction
This part of the Specification sets out the general standards of materials to be supplied and the
workmanship required to be ensured by the Concessionaire. All components parts of the Works
shall, unless otherwise specified, comply with the provisions of this part or be subject to the
approval of the Executing Agency. Particular attention shall be paid to a neat orderly well-arranged
installation carried out in a methodical competent manner.
2. Reference Specifications and Standards
Where reference is made in the Specification to a British Standard Specification (hereinafter

abbreviated to 'B.S') issued by the British Standards Institution of 2, Park street, London W.I., or
to an Indian Standard Specification (I.S.) issued by the Bureau of Indian Standards, (earlier known
as Indian Standard Institution), Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110 002
or American Society for testing and materials (ASTM) issued by ASTM 1916 Race Street,
Philadelphia, P.A., 19103, U.S.A. or American National Standards Institute (ANSI) issued by
ANSI 1430, Broadway, New York, N.Y., 10018, U.S.A. or Japanese Industrial Standards (JIS)
issued by Japanese Standards Association, 4-1-24, Akasaka, Minato-Ku, Tokyo 107, Japan or to
any other equivalent Standard it shall be to the latest revision of that Standard at the Tender opening
date.
The Concessionaire may propose at no extra cost to the Executing Agency, the use of any relevant
authoritative internationally recognised Reference Standard, including Indian Standard (IS).
All details, materials and equipment supplied and workmanship performed shall comply with these
Standards. If Concessionaire offers equipment to other Standards, the equipment/material should
be equal or superior to those specified and full details of the difference shall be supplied.
In the event of conflict between any of these Specifications and the Codes referred,
suchSpecifications shall be defined, prepared by the Concessionaire and submitted to the
ProjectEngineer for approval. The decision of Project Engineer in such case shall be final and
binding on the Concessionaire.Certain specifications issued by national or other widely recognised
bodies are referred to in this Specification. Such specifications shall be defined and referred to
hereinafter as Standard Specification. In referring to the Standard Specifications the following
abbreviations are used:
IS : Indian Standard
ANSI : American National Standards Institute
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society of Testing and Materials
AWS : American Welding Society
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AWWA : American Water Works Association
ISO : International Organisation for Standardisation
JIS : Japanese Industrial Standard
DIN : Deutsches Institute for Normung
BS : British Standards
JWWA : Japanese Water Works Association
IEC : International Electro technical Commission
IEE : Institution of Electrical Engineers
IEEE : Institution of Electrical and Electronic Engineers
NEMA : National Electrical Manufacturer's Association
AGMA : American Gear Manufacturer's Association
3. Materials - General
All materials incorporated in the Works shall be the most suitable for the duty concerned and shall
be new and of reputed make/approved quality, free from imperfections and selected for long life
and minimum maintenance. Non-destructive tests, if called for in the Specification, shall be carried
out. All submerged moving parts of the Plant, or shafts and spindles, etc. of the submerged moving
parts or the faces etc. in contact with them shall be of corrosion resistant materials. All parts in
direct contact with various chemicals, shall be completely resistant to corrosion, or abrasion by
these chemicals, and shall maintain their properties without ageing due to the passage of time,
exposure to light or any other cause.
4. Workmanship - General
Workmanship and general finish shall be of first class quality and in accordance with best workshop
practice.
All similar items of the Plant and their component parts shall be interchangeable. Spare parts shall
be manufactured from the same materials as the originals and shall fit all similar items. Machining
fits on renewable parts shall be accurate and to specified tolerances so that replacements can be
readily installed. All equipment shall operate without excessive vibration and with minimum noise.
All revolving parts shall be truly balanced both statically and dynamically so that when running at
normal speeds at any load upto the maximum there shall be no vibration due to lack of balance.
All parts, which can be worn or damaged by dust, shall be totally enclosed in dust proof housings.
All materials incorporated in the Works shall be the most suitable for the duty concerned, free from
imperfections and selected for long life and minimum maintenance. All necessary accessories
required for satisfactory and safe operation of the Plant shall be supplied by the Concessionaire
unless it is specifically excluded from his scope. Suitable provision by means of eyebolts or other
means are to be provided to facilitate handling of all items that are too heavy or bulky for lifting
and carrying by two men.
If, after installation, the operation or use of the materials or equipment furnished by the
Concessionaire proves to be unsatisfactory, the Executing Agency shall have the right to operate
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or use such materials or equipment until correction of defects, errors or omissions, by repair or by
partial or complete replacement, can be made without interfering with the Plant operations.
5. Welding
Welding shall comply with the latest revision of the BS 5135 Code.
Welders shall be qualified in accordance with the requirement of the appropriate section of BS
4871. The Executing Agency shall have the right to call for further qualifications from time to time
from any welder who in the opinion of the Engineer does not produce weld in accordance with the
qualifications. Each welder shall be assigned a number and letter. Each weldments shall clearly be
identified as to its welder marking the welder's Code adjacent to the welds. A record chart shall be
maintained for each welder showing the procedures for which he has qualified, the date of such
qualification, the type of defects produced and their frequency. The Executing Agency shall
disqualify the welder whose Work requires disproportionate repairs.
Inspection and quality of surveillance shall not be limited to the examination of finished welds. The
techniques employed shall be based on methods which are known to produce good results and
which have been verified at Site by actual demonstration.
Haphazard striking of the electrodes for establishing an arc shall not be permitted. The arc shall be
struck either on the joint or on a starting tag, The starting tag shall be of the same material or a
material compatible with the base metal base being welded. In case of any inadvertent strike on
place other than the welding, the area affected shall be ground flushed and examined by liquid
penetration method.
Generally, a stringer bead technique shall be used with a slight oscillation if necessary to avoid slag
and to minimise the number of beads needed to fill exceed 3 times the wire diameter. Vertical welds
shall be made in upward direction. For all pipes above 300 mm dia, welding shall be done wherever
possible, by two (2) welders working simultaneously along both sides of the pipe.
The root pass shall have less than 1.5 mm internal reinforcement.
Final welds shall be suitable for appropriate fabrication of the non-destructive examination of the
weld. If grinding is necessary, the weld shall be blended into the parent metal without gouging or
thinning of the parent metal in any way. Uneven and excessive grinding may be a cause for
rejection. Fillet weld shall preferably be convex and free from undercutting and overlap at the toe
of weld. Convexity and concavity shall not exceed 1.5 mm. The leg lengths shall not exceed the
specified size by more than 1.5 mm.
All attachments such as lugs, brackets and other non-pressure parts shall also be done by qualified
welders in accordance with the design details and materials specifications. Temporary attachments
shall be removed in a manner that will not damage the parent metal. Area of temporary attachments
shall be dressed smooth and examined by ultrasonic or liquid penetration methods.
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All tack welds shall be made using qualified procedure and welders, the number of size of tack
welds shall be kept as small as to consist of adequate strength and joint alignments. All tack welds
shall be examined visually for defects and if found defective shall be completely removed. As
welding proceeds, tack welds shall be either removed completely or shall be properly prepared by
grinding or filling their starting ends so that they may be satisfactorily incorporated in the welds.
Unacceptable defects shall be removed by grinding machine or chipping or gouging. Flame
gouging may be permitted provided gouged surfaces are ground at least by 1.0 mm below the
deepest indentation.
All weld repairs shall be carried out using the approved welding procedures and welders. Re-
welded areas shall be re-examined by the methods specified for the original welds and repair
procedures shall be duly qualified by the Executing Agency's Representative.
6. Pre-heating and Post-heating Treatment
Pre-heating and post heating treatment shall conform to the relevant application Codes. Pre-heating
not exceeding 121 deg. C for all carbon steel construction above 25 mm thickness would be
mandatory. Such pre-heating would be maintained during flame cutting, flame or arc gouging,
welding and repairs and may be done by gas heating by gas torches/gas rings with neutral flame.
The temperature shall be checked by temperature indicating crayons. However, such pre-heating
will not be necessary for welds less than
6 mm size.
7. Electrodes
All electrodes shall be stored in their original sealed containers under dry conditions. Electrodes
shall remain identified until consumed. All electrodes shall be dried before use. Drying ovens shall
be provided in Work areas for drying purposes. Electrodes withdrawn from oven shall be promptly
used and excess unused electrodes shall be promptly returned to oven.
8. Examination / NDT / Radiography
The various stages of examination and types shall be as stipulated in the respective fabrication
Codes subject to the Executing Agency's approval.
9. Stainless Steel welding
All welding consumable such as electrodes, filler weirs, argon gas for shielding and purging shall
be of high quality and the proposed brand shall be furnished for approval of the Executing Agency.
Weld deposits shall have similar or higher physical properties and similar chemical composition to
the members joined.
All electrodes shall be purchased in sealed containers only and stored in their packing intact. The
packets opened shall be consumed as early as possible. The electrodes removed from the containers
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shall be kept in holding ovens at temperatures recommended by electrode manufacturer. Special
care shall be taken in avoiding mixing of electrodes in the oven. The electrodes and filling wires
shall be free from rust, oil, grease, earth and other foreign matter.
Argon gas with purity 99.5% shall be used for shielding and purging. The purity of gas shall be
certified by the gas manufacturers.
Non-destructive examination of the welds shall be carried out to ensure quality of weld.
The electric current for welding shall be direct current, straight polarity (electrode negative). The
welding current shall be kept minimum possible to ensure minimum heat affected zone in the parent
material. Other side of the weld joint shall be periodically flushed with argon gas.
10. Castings
Cast iron shall be of standard grey close-grained quality. The structure of the castings shall be
homogeneous and free from non-metallic inclusions and other injurious defects. All surfaces of
castings which are not machined shall be smooth and shall be carefully fettled to remove all foundry
irregularities.
Minor defects in depth not exceeding 12.5 percent of total metal thickness and which will not
ultimately affect the strength and serviceability of the casting may be repaired by approved welding
techniques. The Executing Agency shall be notified of large defects and no repair welding of such
defects shall be carried out without prior approval of the Executing Agency. If the removal of metal
for repair should reduce the stress resisting cross section of the casting by more than 25 percent, or
to such extent that the computed stress in the remaining metal exceeds the allowable stress by more
than 25 percent, then casting shall be rejected. Test coupons cast simultaneously with the main
castings shall be identified to check physical, chemical analysis of casting. Major defects on casting
are not acceptable. Castings repaired by welding for minor defects shall be stress-relieved after
such welding. Non-destructive tests as directed by the Executing Agency will be required for any
casting containing defects whose extent cannot otherwise be judged, or to determine where repair
welds have been properly made.
11. Forging
All major stress-bearing forging shall be made to a Standard Specification. Forging shall be
subjected to magnetic particle testing or dye penetration test at the areas of fillets and change in
section. The testing shall be conducted after rough machining (10 microns). Any defect which will
not machine out during the final machining, will be gouged out fully, inspected by dye penetration
or magnetic particle inspection to ensure that the defect is fully removed and repaired using an
approved repair procedure. Any indication, which proves to penetrate deeper than 2.5% of the
finished thickness of the component, shall be reported to the Executing Agency giving the details
like location, length, width and depth. For the magnetic particle inspection, the choice of wet or
dry particles shall be at the Concessionaire's discretion.
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All forging shall be demagnetized after test and shall be heat treated for the relief of residual
stresses.
12. Design life
The Works as a whole shall be new, of sound workmanship, robustly designed for a long reliable
operating life and shall be capable of 24 hours per day continuous operation for prolonged period
in the climatic and working conditions prevailing at the Site, and with the minimum of maintenance.
Particular attention shall be given to temperature changes, the stability of paint finish for high
temperatures, the rating of engines, electrical machinery, thermal overload services, cooling
systems and the choice of lubricants for possible high and prolonged operating temperatures. The
Concessionaire shall be called upon to demonstrate this for any component part either by service
records, or evidence of similar equipment already installed elsewhere or relevant type tests. Routine
maintenance and repair shall as far as possible not require the services of highly skilled personnel.
All equipment covered by this specification shall be designed to provide a minimum design service
life of 20 years.
The plant shall be designed to provide easy access to and replacement of components parts, which
are subject to wear, without the need to replace whole units. No parts in contact with water shall
have a life from new to replacement or repair of less than five years. Where major dismantling is
unavoidable to replace a part, the life of such part shall not be less than ten years.
Design features shall include the protection of Plant against damage caused by vermin, dirt, dust
and dampness and to reduce risk of fire. Plant shall operate without undue vibration, and parts shall
be designed to withstand the maximum stresses under the most severe condition of normal service.
Materials shall have a high resistance to change in their properties due to the passage of time,
exposure to light, temperature and any other cause, which may have a detrimental effect upon the
performance of life of the Works.
Plant located outside lockable areas/building shall have additional features to prevent unauthorised
operation.
13. Lubrication
A complete schedule of recommended oils and other lubricants shall be furnished by the
Concessionaire. The number of different types of lubricants shall be kept to a minimum. The
schedule and the name of the supplier of the lubricants shall be submitted to the Executing Agency.
Concessionaire shall indicate indigenously available equivalent lubricants, with complete

specification, to enable the Executing Agency to arrange for regular supply.
Where lubrication is effected by means of grease, preference shall be given to a pressure system,
which does not require frequent adjustment or recharging. Frequent, for this purpose, means more
than once in a month and grease systems having shorter periods between greasing should be
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avoided. Where necessary for accessibility grease nipples shall be placed at the end of the extension
piping, and, when a number of such points can be grouped conveniently, the nipples shall be
brought to a battery plate mounted in a convenient position. All grease nipples shall be of the same
size and type for every part of the Plant. Arrangements shall be provided to prevent bearings being
overfilled with either grease or oil.
Where more than one special grease is required, a grease gun for each special type shall be supplied
and permanently labeled.
Oil containers shall be supplied complete with oil level indicators of the sight glass type, or where
this is not practicable, with dipsticks. The indicators shall show the level at all temperatures likely
to be experienced in service. The levels shall be clearly visible in the sight glass type from the
normal access floor to the particular item of Plant and they shall be easily dismantled for cleaning.
All sight glasses shall be firmly held and enclosed in metal protection in such manner that they
cannot be accidentally dislodged.
All lubrication systems shall be designed so as not to cause a fire or pollution hazard and particular
care shall be taken to prevent leakage of lubricants and to avoid leaking lubricants coming into
contact with any electrical equipment, heated surfaces or any other potential source of fire.
14. Name Plate
Each item of the Plant shall have permanently attached to it in a conspicuous position, a nameplate
and rating plate. Upon these shall be engraved or stamped, the manufacturer's name, type and serial
number of Plant, details of the loading any duty at which the item of Plant has been designed to
operate, and such diagrams as may be required by the Executing Agency. All indicating and
operating devices shall have securely attached to them or marked upon them designations as to
their function and proper manner of use.
Nameplates, rating plates and labels shall be of a no flame propagating materials, either non-
hygroscopic or transparent plastic with engraved lettering of a contrasting colour. Fixing shall be
by means of non-corrosive screws; drive rivets or adhesives shall not be used.
Warning labels shall be provided where necessary to warn of dangerous circumstances or

substances. Inscriptions or graphic symbols shall be black on a yellow background.
Instruction labels shall be provided where safety procedures such as wearing of protective clothing
are essential to protect personnel from hazardous or potentially hazardous conditions. These labels
shall have inscriptions or graphic symbols in white on a blue background.
15. Nuts, Bolts, Studs and Washers
Nuts, bolts, studs and washers for incorporation in the Plant shall conform to the requirements of
the appropriate standard. Nuts and bolts shall be of the best quality of specified grade, machined
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on the shank and under the head and nut. Bolts shall be of one piece construction and shall be of
sufficient length so that only one thread shall show through the nut in the fully tightened condition.
Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the screwed
portion of such a diameter that it will not be damaged in driving and shall be marked in a
conspicuous position to ensure correct assembly at Site.
Washers, locking devices & anti-vibration arrangements shall be provided where necessary.
Jointing hardware for the entire Plant shall be provided with sufficient spares to cater for site losses.
Where bolts pass through structural members taper washers shall be fitted, where necessary, to
ensure that no bending stress is caused in the bolt. Where there is a risk of corrosion, bolts, nuts
and studs shall be designed so that the maximum stress does not exceed half the yield stress of the
material under any conditions. All bolts, nuts and washers which are subject to frequent adjustment
or removal in the course of maintenance and repair shall be made of nickel-bearing stainless steel.
The Concessionaire shall supply all holding down, alignment and levelling bolts complete with
anchorage, nuts, washers and packaging’s required to attach the Plant to its foundations, and all
bedplates, frames and other structural parts necessary to spread the loads transmitted by the Plant
to concrete foundations without exceeding the design stresses.
16. Allowance for Wastage
The Concessionaire shall supply reasonable excess quantities to cover wastages of those
consumable, which will be normally subject to waste during erection, commissioning and setting
to Work.
17. Painting - General
The Concessionaire shall be responsible for the cleaning, preparation for painting and priming or
otherwise protecting, as specified, all parts of the plant at the place of manufacture prior to packing.
Parts may be cleaned but surface defects may not be filled in before testing at the manufacturer's
works. Parts subject to hydraulic test shall be tested before any surface treatment. After test, all
surfaces shall be thoroughly cleaned and dried out, if necessary by washing with an approved
dewatering fluid prior to surface treatment. Except where the specification provides to the contrary
all painting materials shall be applied in strict accordance with the paint manufacturer's instructions.
All protective coatings shall be suitable for use in warm humid climates. All primers, under coats
and finishes shall be applied by brush or airless spray, except where otherwise specified.
Consecutive coats shall be in distinct but appropriate shades. All paints shall be supplied from the
store to the painters, ready for application, and addition of thinners or any other material shall be
prohibited.
18. Painting at Place of Manufacture
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Steel and cast iron parts shall be sand blasted to near white cleaning before painting. Edges, sharp
curves etc. shall be ground to a curve before sand blasting. A primer coat of zinc rich epoxy resin-
based coating with atleast a 50 microns dry film thickness is to be provided. In addition, the parts
are to be provided with adequate number of coats coal tar epoxy polyamine coating to dry the
thickness of 150 microns including primer coating.
19. Painting at Site
Immediately on arrival at the site, all items of plant shall be examined for damage to the paint coat
applied at the manufacturer's works, and any damaged portions shall be cleaned down to the bare
metal, all rust removed and the paint coat made good with similar paint.
Before final painting is commenced, the Concessionaire shall submit for the approval of Executing
Agency's Representative, full details of the paints he proposes to use together with colour charts
for the gloss finishes. After erection, such items, which are not finish painted, shall be done so and,
items that have been finish painted at the manufacturer's works shall be touched up for any damaged
paintwork.
The dry paint film thickness shall be measured by Electrometer or other instruments approved by
the Executing Agency. In order to obtain the dry film thickness specified, the Concessionaires shall
ensure that the coverage rate given by the paint manufacturer will enable the thickness to be
obtained. Painted fabricated steel work which is to be stored prior to erection shall be kept clear of
the ground and shall be laid out or stacked in an orderly manner that will ensure that no water or
dirt can accumulate on the surface. Suitable packagings shall be laid between the stacked materials.
Where cover is provided, it shall be ventilated.
20. Noise and Vibration
The Concessionaire shall provide a quiet installation. All items of Plant and equipment shall be
carefully chosen with a view to minimising sound levels and also maintain the noise level at STP
Boundary is 45 db(A) in day time and night time).
The Concessionaire shall provide and fix all material for the prevention of transmission of noise
and vibration through the structure. Where appropriate Plant shall be mounted on resilient
mountings in such a manner that the Plant foundations are isolated from the floor or structure. In
addition, all rotating Plant shall be statically and dynamically balanced. Mechanical vibration shall
be eliminated by the use of anti-vibration mountings and flexible connections to ensure an isolation
efficiency of 95% from the building structure. Accordingly, blower room to be kept away from
admin block.
21. Galvanising
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Wherever galvanising has been specified, the hot dip process shall be used. The galvanised coating
shall be of uniform thickness. Weight of zinc coatings for various applications shall not be less than
those indicated below:
(a) Fabricated steel
Thickness less than 2 mm

but not less than 1.2 mm 340 gms/sq.m
Thickness 2 mm and above 460 gms/sq.m
(b) Fasteners
Up to nominal size M10 270 gms/sq.m

Over M10 300 gms/sq.m
Galvanising shall be carried out after all drilling, punching, cutting, bending and welding operations
have been carried out. Burrs shall be removed before galvanizing. Any site modification of
galvanised parts should be covered well by zinc rich primer and aluminium paint.
22. Support for pipework & Valves
All necessary supports, saddles, slings, fixing bolts and foundation bolts shall be supplied to support
the pipe work. Valve and other facilities mounted in the pipe work shall be supported independent
of the pipes to which they connect.
121
Section G3
General Civil Specifications
122
Section G3: General civil specifications
Sl. No. Sub-Section Title

1. C1 Earthwork in grading, excavation and backfilling
2. C2 Technical specifications for properties, storage and handling of common
building materials.
3. C3 Technical specifications for Cast-in-situ concrete & allied works
4. C4 Technical specifications for masonry & allied works
5. C5 Technical specifications for plastering & allied works
6. C6 Technical specifications for flooring and other allied works
7. C7 Technical specifications for roof water proofing insulation and allied
works
8. C8 Technical specifications for painting, white washing etc.
9. C9 Technical specifications for fabrication and erection of structural steel
works
Annexure B - Inspection, testing and quality checklist along with
addendum.
10. C10 Technical specifications for Glass and Glazing
11. C11 Technical specifications for MS doors, windows, ventilators and louvers
12. C12 Technical specifications for rolling steel shutters / grills
13. WS1 Technical specifications for laying of pipes and fittings / specials
14. WS2 Technical specifications for laying and jointing of cast iron pipes and
fittings (Cast iron).
123
Sub-section - C1
Technical specification for excavation and backfilling
124
Sub Section - C1
Technical specification for excavation and backfilling
Contents
Clause no. Description Page nos.
1.1 Scope ......................................................................................................................................... 126

1.2 General requirements ................................................................................................................ 126
1.3 Codes and standards .................................................................................................................. 127
1.4 Excavation................................................................................................................................. 128
1.5 Filling ........................................................................................................................................ 129
1.6 Sampling testing and quality control ........................................................................................ 132
125
Sub Section - C1: Technical specification for excavation and backfilling
1.1 Scope
This section of the specification covers the technical requirements for excavation and filling for
industrial plots in & around structures, buildings, pipes, foundations, trenches, pits, drains,
channels, cable ducts, underground facilities & similar works. It also covers filling areas and plinths
with selected materials, conveyance and disposal of surplus soils and/or stacking them properly as
directed by the Project Engineer and Executing Agency.
The Concessionaire shall be fully responsible for proper setting out of works, profiling in
excavation, stacking, etc., taking adequate safety measures etc. The Concessionaire shall carry out
all works meant within the intent of this specification even if not explicitly mentioned herein. All
work shall be executed to the satisfaction of the Project Engineer and Executing Agency.
Existing trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings, pipelines,
drains, sewers, or other surface or subsurface systems/drains/facilities within or adjacent to the
works being carried out which are not to be disturbed, shall be protected from damage by the
Concessionaire shall provide and install suitable safeguards approved by the Project Engineer and
Executing Agency for this purpose.
During excavation, the Concessionaire shall take all necessary precautions against soil erosion,
water & environmental pollution and where required to undertake additional works to achieve this
objective. Before start of operations, the Concessionaire shall submit to the Project Engineer and
Executing Agency for approval, his work plan and the procedure he intends to follow for disposal
of waste materials etc. and the schedule for carrying out temporary and permanent control works.
However, the approval of the Project Engineer and Executing Agency to such plans and procedures
shall not absolve the Concessionaire of his responsibility for safe and sound work.
1.2 General requirements
The Concessionaire shall make his own surveying arrangements for locating the coordinates and
positions of all work and establishing the reduced levels (RL’s) at these locations based on two
reference grid lines and one benchmark, which will be furnished by the Executing Agency. The
Concessionaire has to provide at site all the required survey instruments, along with qualified
surveyors, to the satisfaction of the Project Engineer and Executing Agency so that the work can
be carried out accurately and according to the specification and drawings.
The Concessionaire shall furnish all skilled and unskilled labour, plant, tools, tackle, equipment,
men, materials required for complete execution of the work in accordance with the drawings and
as described herein and/or as directed by the Project Engineer and Executing Agency.
126
The Concessionaire shall control the grade in the vicinity of all excavations so that the surface of
the ground will be properly sloped or dyed to prevent surface water from running into the excavated
areas during construction.
All materials obtained from excavation shall remain Executing Agency’s property. All salvaged
materials of archeological importance or of value (in the opinion of the Project Engineer and
Executing Agency) shall be segregated from the other materials and both stacked separately and in
regular manner at locations indicated by the Project Engineer and Executing Agency.
Excavation shall include removal of trees including roots & organic remains, vegetation, grass,
bushes, shrubs, plants, poles, fences, etc. that are in the area to be excavated as well as beyond the
excavation line so as to ensure safety of the excavated side slopes, and of men and equipment
operating in the area. Before start of excavation work, joint measurements of ground level shall be
taken after cleaning all grass, vegetation, etc.
Excavation shall include the removal of all materials required to execute the work properly and
shall be made with sufficient clearance as decided by the Project Engineer and Executing Agency
to permit the placing and setting of forms, inspection and completion of all works to the satisfaction
of the Project Engineer and Executing Agency for which the excavation was done.
Wherever reference is made to ‘drawings’ in this specification it shall mean the latest issue of the
approved drawings.
1.3 Codes and standards
All standards, specifications, acts, and codes of practice referred to herein shall be the latest editions
including all applicable official amendments and revisions.
In case of conflict between this specification and those (IS standards, codes etc.) referred to herein
(in para 3.3) the former shall prevail.
Some of the relevant Indian standards, Acts and Codes are referred to here below:
IS:383 - Specification for coarse and fine aggregates from natural sources for concrete.
IS:2720 - (Part - II, IV to VIII, Methods of tests for soils - determination of water XIV, XXI,
XXIII, XXIV content etc. XXVII to XXIX, XL)
IS:3764 - Safety code for excavation work
IS:4081 - Safety code for blasting and related drilling operations
IS:4701 - Code of Practice for earth work on canals
IS:9759 - Guide lines for Dewatering during construction.
IS:10379 - Code of practice for field control of moisture and compaction of soils for embankment
and sub-grade.
IS:3812 - Pulverized fuel ash - specification part 2 for use as admixture in cement mortar and
concrete
127
1.4 Excavation
Excavation in all types of soils, soft and disintegrated rock (ordinary rock), and hard rock shall be
done up to the required level. Excavation shall also include breaking of existing concrete RCC,
Masonry work, tar and bitumen surfaces, and paving works etc. In case blasting is required, the
same shall be subject to the approval of Project Engineer and Executing Agency. Sides and bottoms
of excavation shall be cut sharp and true to line and level. Undercutting shall not be permitted.
When machines are used for excavation, the last 300 mm before reaching the required level shall
be excavated manually or by such equipment that soil at the required final level will be left in its
natural condition. Suitability of strata (at the bottom of excavations) for laying the foundation
thereon shall be determined by the Project Engineer and Executing Agency.
Excavation for foundations shall be to the bottom of lean concrete and as shown on drawings or as
directed by the Project Engineer and Executing Agency. The bottom of all excavations shall be
trimmed to required levels and when excavation is carried below such levels, by error, it shall be
brought back to specified level by filling with concrete of nominal mix 1:3:6/1:4:8 (cement & Fly
ash (20% replacement ratio of cement with fly ash): coarse sand: 20 mm down aggregates) as
The Concessionaire shall ascertain for himself the nature of materials to be excavated and the
difficulties, if any, likely to be encountered in executing this work. Cofferdams, Sheeting, shoring,
bracing, maintaining suitable slopes, draining etc. shall be provided and installed by the
Concessionaire, to the satisfaction of the Project Engineer and Executing Agency.
All excavation for installation of underground facilities, such as piping, sewer lines, drain lines,
etc. shall be open cuts. For deep and huge excavations and in other excavations, if required by the
Project Engineer and Executing Agency, the Concessionaire shall submit for Project Engineer and
Executing Agency’s approval showing the methodology to be adopted for excavation in order to
maintain the stability of side slopes, means for ensuring safety of existing facilities nearby,
dewatering as required etc. However, the Concessionaire shall be fully responsible for the scheme
irrespective of any approvals granted. Benching shall be provided for deeper excavation wherever
required.
When excavation requires bracing, sheeting or shoring etc., the Concessionaire shall submit
drawings to the Project Engineer and Executing Agency, showing arrangements and details of
proposed installation. The Concessionaire shall also furnish all supporting calculations as called
for and shall not proceed until he has received written approval from the Project Engineer and
Executing Agency. However, the responsibility for adequacy of such bracing, sheeting, shoring
etc. will rest with the Concessionaire, irrespective of any approval of the Project Engineer and
Executing Agency. All precautions shall be taken while excavations near existing structures are to
be carried out till the backfilling is completed.
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The Concessionaire shall have to constantly pump out any water collected in excavated pits and
other areas due to rain water, ground water, springs etc. and maintain dry working conditions at all
times until the excavation, placement of reinforcement, shuttering, concreting, backfilling is
completed. The Concessionaire shall remove all slush/muck from the excavated areas to keep the
work area dry. Sludge pumps, if required, shall be employed by the Concessionaire for this purpose.
The Concessionaire shall remove all materials arising from excavations from the vicinity of the
work either for direct filling, stacking and subsequent filling or for ultimate disposal as directed by
the Project Engineer and Executing Agency. In no case shall the excavated soil be stacked within
a distance of 1.5m from the edge of excavation or one third the depth of excavation whichever is
more. Material to be used for filling shall be kept separately as directed by the Project Engineer
and Executing Agency.
1.5 Filling
1.5.1 Materials
a) Materials to be used for filling purposes shall be stone, sand or other inorganic materials and
they shall be clean and free from shingle, salts, organic, large roots and excessive amount of
sod. Lumps concrete or any other foreign substances which could harm or impair the strength
of the substructure in any manner. All clods shall be suitably broken to small pieces. When
the material is mostly rock boulders, these shall be broken into pieces not larger than 150
mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines
less than 5 microns shall not be more than 20%. In any case, the materials to be used for
filling purposes shall have the prior written approval of the Project Engineer and Executing
Agency.
b) If excavated materials are to be used for filling, then the Concessionaire shall select the
materials from the stockpile, load and transport this material and execute the filling. This
shall include excavation of earth which may become hard due to laying in stack yard for a
long period of time.
c) In case the materials have to be brought from pits/quarries, then it shall be the
Concessionaire’s responsibility for identification of such quarry areas, obtaining approval for
their use from concerned authorities, excavation/quarrying, loading and carriage of such
material, unloading and filling at specified locations. The Concessionaire shall pay any fees,
royalties etc. that may have to be paid for utilization of borrow areas.
1.5.2 Filling procedure
a) After completion of foundation, footings, walls and other construction below the elevation
of the final grades, and prior to filling, all temporary shoring, timber, etc. shall be sequentially
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removed and the excavation cleaned of all trash, debris and perishable materials. Filling shall
begin only with the written approval of the Project Engineer and Executing Agency. Also,
areas identified for filling shall be cleared of all soft pockets, vegetation, bushes, slush etc.
In case of plinth and similar filling the ground shall be dressed and consolidated by ramming
and light rolling.
b) Fill materials shall not be dropped directly upon or against any structure or facility where
there is danger of displacement or damage. Filling shall be started after the concrete /
masonry has fully set and shall be carried out in such manner so as not to cause any undue
lateral thrust on any part of the structure.
c) All space between foundation (concrete or masonry) and the sides of excavation shall be filled
to the original surface after making allowance for settlement. Backfilling of earth shall be
carried out as per IS/CPWD Specifications. Each layer shall be watered and compacted with
proper moisture content and with such equipment as may be required to obtain a
compaction/density as specified. Trucks or heavy equipment for depositing or compacting fill
shall not be used within 1.5 metres of building walls, piers or other facilities which may be
damaged by their weight or operations. The methods of compaction shall be subject to the
approval of the Project Engineer and Executing Agency. Pushing of earth for filling shall not
be adopted under any circumstances.
d) Fill adjacent to pipes shall be free of stones, concrete, etc. and shall be hand placed and
compacted uniformly on both sides of the pipe and where practicable up to a minimum depth
of 300 mm over the top of pipes. While tamping around the pipes, care should be taken to
avoid unequal pressure.
e) Filling shall be accurately finished to line, slope, cross section and grade as shown on the
drawings. Finished surface shall be free of irregularities and depressions and shall be within
20 mm of the specified level.
f) Where filling with stone from excavated materials is required, as per design and functional
requirements, it shall be from broken pieces of boulders. At first a 75mm thick cushion of
selected earth shall be laid over which the 200 mm thick graded stones shall be laid in loose
layers of 200 mm and then the interstices filled with properly graded fine materials consisting
of selected earth brought from borrow areas. Each layer shall be watered and compacted to
the required density as per design and functional requirements before the next layer is laid.
However, no cushion shall be required where filling is over non-rocky surface.
g) Where clean stone fill is required as per design and functional requirements it shall consist
of clean selected stone metal of 40 mm nominal size. It shall be laid in layers not exceeding
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150 mm (loose) and lightly tamped before the next layer is laid. No compaction shall be
required for this type of stone filling.
1.5.3 Compaction
a) Where compaction of 90% Standard Proctor Density is called for, such compaction shall be
by mechanical means but the Concessionaire may be permitted to adopt manual means only
if the Project Engineer and Executing Agency finds that the desired compaction is achievable
in the field.
b) Where compaction to 95% Standard Proctor Density is called for, it shall be by mechanical
means only. Where access is possible, compaction shall be 12 tonne rollers smooth wheeled,
sheep foot or wobbly wheeled and directed by the Project Engineer and Executing Agency.
A smaller weight roller may be permitted by the Project Engineer and Executing Agency in
special cases, but in any case not less than 10 passes of the roller will be accepted for each
layer. Each layer shall be wetted or the material dried by aeration to a moisture content of 3-
5% above the Optimum Moisture Content to be determined by Concessionaire. Each layer
shall be watered, rammed and compacted to the density as specified in the Schedule of
Quantities.
c) For compacting each sand layer, water shall be sprayed over it to flood it and it shall be kept
flooded for 24 hours to ensure maximum compaction. Vibro-compactors shall also be used
if necessary to obtain the required degree of compaction. Any temporary works required to
contain sand under flooded condition shall also be undertaken. The surface of the
consolidated sand shall be dressed to required levels or slope.
d) After the compacted fill has reached the desired level, the surface shall be flooded with water
for 24 hours, allowed to dry and then rammed and consolidated to avoid any settlement, at a
later date. The compacted surface shall be properly shaped, trimmed and consolidated to an
even gradient or level. All soft spots shall be excavated, filled and consolidated.
e) The degree of compaction of compacted fill in place will be subject to tests in accordance
with relevant Indian Standards as desired by the Project Engineer and Executing Agency. As
the work progress, the Concessionaire shall provide the necessary facilities to make such
tests. If any test indicates that the compaction achieved is less than the required as per design
and functional requirements degree of compaction, the Project Engineer and Executing
Agency may require all fill placed subsequent to the last successfully test to be removed and
re-compacted by the Concessionaire. Compaction procedure shall be amended as necessary
to obtain satisfactory results.
f) When semi-compacted fill is required as per design and functional requirements by the
Project Engineer and Executing Agency, the Concessionaire shall fill up such areas with
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available earth from stockpiles or borrow pits or directly from excavation without special
compaction except that obtained by moving trucks, etc.
1.6 Sampling testing and quality control
1.6.1 General
a) The Concessionaire shall carry out all sampling and testing in accordance with the relevant
Indian Standards and/or International Standards and shall conduct such tests as are called for
by the Project Engineer and Executing Agency. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to
the directions of the Project Engineer and Executing Agency. Tests shall be done in the field
and at a laboratory approved by the Project Engineer and Executing Agency and the
Concessionaire shall submit to the Project Engineer and Executing Agency, the test results
in triplicate within three days after completion of a test. The Project Engineer and Executing
Agency may, at his discretion, waive some of the stipulations given below, for small and
unimportant operations.
b) Work found unsuitable for acceptance shall be removed and replaced by the Concessionaire.
The work shall be redone as per specification requirement and to the satisfaction of the
Project Engineer and Executing Agency.
c) Only as a very special case and that too in non-critical areas, the Project Engineer and
Executing Agency may accept filling work which is marginally unacceptable as per the
criteria laid down. For such accepted work, payment shall be made at a reduced rate prorate
to the compaction obtained against that stipulated.
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1.6.2 Quality Assurance and Quality Control
The Concessionaire shall submit and finalize a detailed field Quality Assurance and Quality Control
of the Contract according to the requirements of the specification prior to commencement of works.
The document should include the procedure to be adopted by concessionare for QAQC during
execution of works including responsibilities of following QAQC and checking methodology. The
QAQC document shall also comprises of concessionare’s company policies and nodal officer for
implementation of adopted polices while implementation. The document clearly define the setting
up of a testing laboratory, arrangement of testing apparatus / equipment and frequency of testing,
deployment of qualified/experienced manpower, preparation of format for record, Field Quality
Plan, field permits and inspection schedule for PE and UPJN before execution of any work with
details of confined space /area including dangerous place of working (working on heights/deep
trenches) etc. On finalized field quality plan, the Executing Agency shall identify customer hold
prints beyond which work shall not proceed without written approval from the Project Engineer
and Executing Agency. Frequency of sampling and testing including the methods for conducting
the tests are given in Table - 1. The testing frequencies set forth are the desirable minimum and the
Project Engineer and Executing Agency shall have the full authority to carry out or call for tests as
frequently as he may deem necessary to satisfy himself that the materials and works comply with
the appropriate specifications.
1.6.3 Acceptance criteria
Following acceptance criteria shall be followed.
a) All individual samples collected and tested should pass without any deviation when only one
set of sample is tested.
b) For re-test of any sample two additional samples shall be collected and tested, and both
should pass without any deviation.
c) Where a large number of samples are tested for a particular test than 9 samples out of every
10 consecutive samples tested shall meet the specification requirement.
d) Tolerance on finished levels for important filling areas at approved intervals shall be + 20
mm. However, for an unimportant area, tolerance upto + 57 mm shall be acceptable at the
discretion of the Project Engineer and Executing Agency. However, these tolerances shall
be applicable for localized areas only.
Table 1: Frequency of sampling and testing

Sl. Nature of test/ No. of samples &
Methods of test Remarks
No. characteristics frequency of test
I. Suitability of fill
materials
(a) Grain size analysis IS:2720 (Part-IV) One in every 2000 Cum. Test for and sand
for each type and each
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source of fill material
subject to a minimum of
(b) Liquid limit and plastic IS:2720 (Part-V) two samples Test for soil
limit
(c) Shrinkage limit IS:2720 (Part-VI) One in every 5000 cum. The frequency of Test
for each type shall be
(d) Free sweel index IS:2720 (Part-XL) And each source of fill increased depending on
materials. type of soil
(e) Chemical Analysis IS:2720
i. Organic matter Part XXII One in every 5000 Cum Test for sand and soil.
for each type and each
source of
ii. Calcium carbonate Part XXIII Fill materials.
iii. pH Part XXVI
iv. Total soluble Part XXVII
sulphate
II. Standard proctor test IS:2720 (Part VII) One in every 2000 cum. Test for soil for
for each type and each determining optimum
source of fill materials moisture content, Dry
Density etc.
III. Moisture content of fill IS:2720 (Part II) -do- Test for soil
before compaction.
IV. Degree of compaction (i) For foundation Test for soil
of fill filling, one for every ten
foundations for each
(a) Dry density by core IS:2720 (Part XXIX) Compacted layer.
cutter method However, each layer for
location of important and
heavily loaded
or
Dry density in place by IS:2720 (Part Foundations resting on fill
sand displacement XXVIII) shall be tested.
method
(ii) For area filling one for
every 1000 Sqm. Area for
each compacted layer.
(b) Relative density index IS:2720 (Part XIV) -do- (i) & (ii) Test for sand
(c) Dry density by proctor Standard Practice Random checks to be Test for soil
needle penetration carried out for each
compacted layer in
addition to tests
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mentioned under IV (a)
above.
Sub section - C2
Technical specification for properties, storage and handling of common building materials
135
Sub Section - C2
Technical specification for properties, storage and handling of common building materials
Contents
2.1 Scope ............................................................................................................................................. 137

2.2 General requirements .................................................................................................................... 137
2.3 Codes and standards ...................................................................................................................... 138
2.4 Burnt clay Bricks .......................................................................................................................... 139
2.5 Fly Ash Bricks .............................................................................................................................. 140
2.6 Stones ............................................................................................................................................ 141
2.7 Lime .............................................................................................................................................. 142
2.8 Cement and fly ash........................................................................................................................ 142
2.9 Water ............................................................................................................................................. 143
2.10 Aggregates .................................................................................................................................... 143
2.11 Sand............................................................................................................................................... 144
2.12 Reinforcement steel, structural steel (including embedded steel) and wire mesh......................... 144
2.13 Storage and handling of materials ................................................................................................. 146
2.14 Testing........................................................................................................................................... 149
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Sub Section - C2: Technical specification for properties, storage and handling of common building
materials
2.1 Scope
The scope of this section of the specification is to specify the properties, storage and handling of
common building materials namely, coarse aggregates, cement, water, sand masonry units,
reinforcement and structural steel.
Properties of the materials in general have been discussed. Specific requirements of the materials
have been stipulated separately under specification for relevant items of work.
The work shall include, providing of all necessary plants and equipment, providing adequate
engineering supervision and technical personnel, skilled and unskilled labour etc. as required to
carry out the entire work as directed by the Project Engineer and Executing Agency to his complete
satisfaction.
All materials proposed for use in the work shall conform to the requirements laid down in this
section, and also subject to the approval of the Project Engineer and Executing Agency. After
specific materials have been accepted, the source of supply of such materials shall not be changed
without prior approval of the Project Engineer and Executing Agency.
Approval of any material by the Project Engineer and Executing Agency shall not relieve the
Concessionaire of his responsibility, for the requisite quality and performance of the material used.
Any material considered to be sub-standard, or not upto satisfaction of the Project Engineer and
Executing Agency, shall not be used by the Concessionaire and shall be removed from the site
immediately.
Representative samples shall be procured by the Concessionaire and submitted to the Project
Engineer and Executing Agency, for approval before bulk procurement. The representative samples
shall be retained by the Project Engineer and Executing Agency for future comparison and
reference.
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In the event that state, city or other local governmental bodies have requirements more stringent
than those set forth in this specification, the former shall govern.
All applicable standards, acts, specifications, codes of practice, hand books, referred to herein shall
be the latest editions, including all official amendments and revisions.
In the event of conflict between any of these Specifications and the Codes referred,
suchspecifications shall be defined, prepared by the Concessionaire and submitted to the Project
Engineer for approval. The decision of Project Engineer in such case shall be final and binding on
the Concessionaire.
Any special materials used, but not covered here, shall conform to relevant Indian Standards, if
any, or as specified by the Project Engineer and Executing Agency for any special purpose.
Some of the applicable Indian standards, codes are referred to here below:
IS:226 Specification for structural steel (standard quality).
IS:269 Specification for ordinary Portland cement, 33 grade.
IS:383 Specification for coarse and fine aggregates from natural sources for
concrete.
IS:432 Specification for mild steel and medium tensile steel bars and (Parts
1 & 2) hard-drawn steel wires for concrete reinforcement.
IS:455 Specification for Portland slag cement.
IS:712 Specification for building limes.
IS:1077 Specification for common burnt clay building bricks.
IS:1077 Specification for Burnt clay bricks/Fly ash bricks.
IS:1127 Recommendations for dimensions and workmanship of natural building

stones for masonry work.
IS:1129 Recommendation for dressing of natural building stones.

IS:1489 Specification for Portland pozzolana cement
(Part-I) Fly ash based
(Part-II) Calcined clay based
IS:1542 Specification of sand for plaster.
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IS:1566 Specification hard-drawn steel wire fabric for concrete reinforcement.
IS:1597 Code of Practice for construction of stone masonry, rubble stone masonry.
IS:1786 Specification for high strength deformed bars for concrete reinforcement.
IS:2062 Specification for hot rolled medium and high tensile structural steel.
IS:2116 Specification for sand for masonry mortars.
IS:2386 Testing of aggregates for concrete. (Part I to VIII)
IS:3495 Methods of test of Burnt clay bricks/Fly ash bricks (Part-I to IV)
IS:4031 Methods of physical tests for hydraulic cement.
IS:4032 Methods of chemical analysis of hydraulic cement.
IS:4082 Recommendations on stacking and storage of construction materials at

site.
IS:7969 Safety code for handling and storage of building materials.
IS:8112 High strength ordinary portland cement.
IS:8500 Medium and high strength structural steel.
IS:12269 43/53 grade ordinary Portland cement.
IS:12330 Sulphate resisting Portland cement.
IS:12600 Portland cement, low heat.
IS:12894 Fly Ash Lime Bricks - specification.
IS: 3812-2 Specification for pulverized fuel ash for use as admixture in cement mortar and
concrete
2.4 Burnt clay Bricks
Burnt clay bricks, for general masonry work, shall conform to IS:1077 and for face brick work,
shall conform to IS:2691. Fly ash lime bricks shall conform to IS:12894.
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Bricks for general masonry work shall be table moulded/machine made, well burnt without being
vitrified, of uniform size, shape, having sharp edges and cherry red colour. These shall be free from
cracks, flaws or nodules of free lime and shall emit clear ringing sound (metallic sound) when
struck. These shall not show any signs of efflorescence either when dry or subsequent to soaking
in water. Fractured surface shall show uniform texture free from girts, lumps, holes etc.
Unless otherwise specified, minimum compressive strength shall correspond to class designation
75 as per IS: 107 with a minimum crushing strength of 75 kg/sq.cm. for general masonry work.
However, for non-load bearing walls, bricks pavements, etc. bricks of class designation 50 shall
only be used, wherever specified or shown on the drawings. Water absorption after 24 hours
immersion shall not exceed 20% by weight for common bricks and 15% for face bricks.
On the basis of finish and dimensional tolerance, the bricks shall be classified as sub class A and
B. Dimensional tolerance shall not exceed 3% and 8% of the size, of common bricks for sub-class
A & B respectively and 3% for face bricks. All bricks shall have rectangular faces and sharp straight
edges. Maximum permissible chip page for the face bricks shall be 6mm at the edges and 10mm
for corners. The face bricks shall show no efflorescence after soaking in water and drying in the
shade.
The size of the bricks used shall be either modular size as per IS:1077 or locally available
conventional size as approved by the Project Engineer and Executing Agency.
Each brick shall have the manufacturer’s identification mark clearly marked on the frog. The colour
and texture of face bricks shall be limited to the range of samples submitted. Any brick not found
upto the satisfaction of the Project Engineer and Executing Agency shall be removed immediately
from site by the Concessionaire.
2.5 Fly Ash Bricks
Fly ash bricks (cement bonded) shall be locally made. Bricks shall have smooth rectangular faces
with sharp and square corners. Bricks shall be hand or machine moulded and shall be made from
the admixture of suitable good quality of fly ash, sand and cement as per the composition mentioned
below:
o Fly ash : 50-60%

o Sand : 32-40%
o Cement : 8-12%
The fly ash bricks will be as per latest relevant IS code. The bricks will be of dimension as per
standard clay brick, suitable for making 230 mm thick full brick wall, 115 mm thick half brick wall
and 75 mm thick minor partition walls, as applicable, as per drawing/specification/BOQ. A
maximum tolerance of (+/-) 2 mm shall be allowed as the manufacturing tolerance. The bricks shall
have frog of 100 mm in length 40 mm in width and 10 to 20 mm deep of one of its flat sides.
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The bricks when tested in accordance with the procedure laid down in IS 3495 (part 2): 1992 after
immersion in cold water for 24 hrs. Water absorption shall be within 13-15% by weight. Similarly,
the porosity of the fly ash bricks shall be within 12-20%. The bricks shall have a minimum crushing
strength of 80 Kg/Sqcm.
Fly ash bricks, for general masonry work, shall conform to IS:2212-1991
Unless otherwise specified, minimum compressive strength shall correspond to class designation
80 as per IS: 107 with a minimum crushing strength of 80 kg/sq.cm. For general masonry work.
However, for non-load bearing walls, bricks pavements, etc. bricks of class designation 50 shall
only be used, wherever specified or shown on the drawings. Water absorption after 24 hours
immersion shall not exceed 20% by weight for common bricks and 15% for face bricks.
On the basis of finish and dimensional tolerance, the bricks shall be classified as sub class A and
B. Dimensional tolerance shall not exceed 3% and 8% of the size, of common bricks for sub-class
A & B respectively. All bricks shall have rectangular faces and sharp straight edges. Maximum
permissible chip page for the face bricks shall be 6 mm at the edges and 10 mm for corners. The
face bricks shall show no efflorescence after soaking in water and drying in the shade.
The size of the bricks used shall be either modular size as per IS:1077 or locally available
conventional size as approved by the Project Engineer and Executing Agency.
Each brick shall have the manufacturer’s identification mark clearly marked on the frog. The colour
and texture of face bricks shall be limited to the range of samples submitted. Any brick not found
upto the satisfaction of the Project Engineer and Executing Agency shall be removed immediately
from site by the Concessionaire.
2.6 Stones
All stones shall be from approved quarries. These shall be hard, tough, and durable, compact
grained, uniform the texture and colour and free from decay, flaws, veins, cracks and sand holes.
The surface of a freshly broken stone shall be bright, clean and sharp and hall show uniformity of
texture, without loose grains and free from any dull, chalky or earthy appearance. Stone with round
surface shall not be used.
Stones showing mottled colours shall not be used for face work. A stone shall not absorb more than
5% of its weight of water after 24 hours immersion. The type of stone shall be as specified or
shown on drawings and/or as instructed by the Project Engineer and Executing Agency. Stones
used for masonry work shall conform to IS:1597 (Part – I) No soft stone shall be used for masonry
or for filling purpose.
Any stone not found up to the satisfaction of Project Engineer and Executing Agency shall be
removed immediately from site by the Concessionaire.
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2.7 Lime
Lime shall be stone lime and it shall conform to IS:712. Hydrated lime shall be mixed with water
to form a putty. This shall be stored with reasonable care to prevent evaporation of water for at
least 24 hours before use. Quick lime shall be slaked with enough water to make a cream and then
stored with reasonable care to prevent evaporation of water for at least seven days before use. Type
of lime to be used for different purposes such as concreting, plastering, white washing etc. shall be
according to the satisfaction made hereunder:
Class – A Eminently hydraulic lime used for structural purposes.

Class – B Semi-hydraulic lime used for masonry mortars, lime concrete and plaster
undercoat
Class – C Fat lime used for finishing coat in plastering, white washing, composite mortars,
etc. and with addition of pozzolanic materials for masonry mortar.
Class – D Magnesium/dolomite lime used for finishing coat in plastering, whitewashing, etc.
Class – E Kankar lime used for masonry mortar.
Class – F Siliceous dolomite lime used for undercoat and finishing coat of plaster
2.8 Cement and fly ash
Cement shall be Portland pozzolana cement conforming to IS:1489 or Portland slag cement
conforming to IS:455 or sulphate resistant cement confirming to IS 12330 as per the specific site
condition and exposure. As per CPHEEO Maunal guideline, all civil works in contact with sewage
shall be constructed with either brick work or RCC and in both cases sulphate resistant cement
alone shall be used. However, any lower grade of OPC, PPC and PSC should never be mixed with
higher grade cement.
Fly ash is generated by burning of coal in coal fired power plants. It has the characteristic of
pozzolonic additive to cement. Continuous research studies by various engineering research
laboratories revealed its varied usefulness as an additive for enhancing the various qualities of
concrete including its workability, strength and durability if handled and cared properly. Partial
replacement of cement with fly ash in concrete save much of the energy required for production of
OPC and also facilitates the economical disposal of millions of tons of fly ash.
At present most of the fly ash blended cements commercially produced in India has 18 to 25% fly
ash by weight and addition of fly ash to this extent has a beneficial effect on the workability and
economy of concrete. It has been found that in order to improve the other qualities of concrete like
resistance of sulfate attack and thermal cracking, larger percentage of fly ash is to be used in
concrete.
Indian standard specification No. 3812-2003, Specification for Pulverized Fuel Ash, Part 2: For
Use as Admixture in Cement Mortar and Concrete [CED 2: Cement and Concrete] covers the
extraction and the physical and chemical requirements of pulverized fuel ash for use as admixture
in cement mortar and concrete. Fly ash confirming to this standard shall be used part replacement
of cement as per IS code 3812.
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The chemical, physical requirements and testing of fly ash shall be in accordance with the IS 3812-
2003 shall be permitted only upon testing and approval by Jal Nigam.
2.9 Water
Water used for cement concrete, mortar, plaster, grout, curing, washing of coarse aggregate,
soaking of bricks, etc. shall be clean and free from injurious amount of oil, acids, alkalis, organic
matters or other harmful substances in such amounts that may impair the strength or durability of
the structure. Potable water shall generally be considered satisfactory for all masonry and concrete
works, including curing. The Concessionaire shall carry out necessary tests in advance to prove the
suitability of the water proposed to be used. As a guide, the following concentrations represent the
maximum permissible values:
a. To neutralize 200 ml sample of water, it should not require more than 2ml of 0.1 normal
NaOH.
b. To neutralize 200 ml sample of water, it should not require more than 10ml of 0.1 normal
HCL.
c. Percentage of solids shall not exceed the following :
1. Organic 0.02
2. Inorganic 0.30
3. Sulphates 0.05
4. Chlorides 0.10
5. Suspended matter 0.20
2.10 Aggregates
Aggregates mean both coarse and fine inert materials used in the preparation of concrete.
Aggregates shall consist of natural sands, crushed stone and gravel from a source known to produce
satisfactory aggregate for concrete and shall be chemically inert, hard, strong, durable against
weathering, of limited porosity and free from such quantities of deleterious materials as may cause
corrosion of reinforcement or may impair the strength and / or durability of the concrete. Total
percentage of all deleterious materials, including coal, lignite, clay lumps, and materials finer than
75 microns, soft fragments and shale but excluding mica shall not exceed 5%. However, for crushed
fine aggregate, total percentage of coal and lignite and clay lumps, shall be limited to 2%. Both
coarse and fine aggregates shall conform to IS:383 for concrete, shotcreting etc. unless otherwise
mentioned.
Sample of aggregates for mix design and determination of their suitability shall be sent to the
laboratory well in advance in scheduled placing of concrete. Sampling, testing, and interpretation
of test results shall be subject to the approval of the Project Engineer and Executing Agency.
Aggregates shall be properly graded.
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2.11 Sand
Sand shall be hard, durable, clean and free from adherent coatings of organic matter and shall not
contain clay balls or pellets. The sand shall be free from impurities such as iron pyrites, alkalis,
salts, coal, mica, shale, or other laminated materials, in such forms or quantities as to affect
adversely the hardening, strength, durability or appearance on mortar, plaster, etc. or to cause
corrosion of any metal in contact with such mortar, plaster etc. In no case, the cumulative
percentage of Impurities in sand shall be more than 5% by weight. All sand shall be properly
graded. Unless otherwise directed by the Project Engineer and Executing Agency, sand for masonry
mortars shall conform to IS:2116 and sand for plaster shall conform to IS:1542. Sand, when used
as fine aggregate, in concrete, shall conform to IS:383. For filling, medium grained sand (having
fines less than 75 microns not exceeding 20%) shall be used.
2.12 Reinforcement steel, structural steel (including embedded steel) and wire mesh
Billet: (Primary steel)
A semi-finished product obtained by forging or rolling, usually square and not exceeding 125 x 125
mm in cross section with rounded corners and is intended for further processing into suitable
finished product by forging or re-rolling.
Steel shall be manufactured by open hearth, electric, duplex, basic oxygen or a combination of
these processes. In case any other process is employed by the manufacturer, prior approval of the
purchaser should be obtained.
The ladle analysis of the material when analyzed in accordance with the various parts of IS: 228,
shall be confirmed with IS: 8056-1976- Table 1 (Chemical composition).
Table 1 Chemical Composition (As per IS: 8056-1976 clauses 3.1 & 6.1)
Constituent Percent
Carbon 0-45 to 0.80
Silicon 0.15 to 0.35
Manganese 0.40 to 1.00
Sulphur, Max 0.050
Phosphorus, Max 0.050
In case of continuous cast billets, the billet analysis shall be taken as ladle analysis.
Permissible variation in case of product analysis from the limits specified in IS: 8056-1976
clause-6.1 shall be as follows:
Variation Over the Specified Maximum or

Constituent
Under the Minimum Limits in %
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Carbon 0.03
Silicon 0.03
Manganese 0.04
Sulphur, Max 0.005
Phosphorus, Max 0.005
Note: Variations shall not be applicable both over and under the specified limits in several
determinations in a heat.
Sampling
At least one ladle sample analysis shall be taken per cast.
If required, the samples for product analysis shall be prepared by forging or rolling down to 30-
mm round section.
In case of wire rods the test piece size shall be the size of wire rods.
Drilling shall be taken from the sample representing two-thirds, half and one-third of height from
bottom of the billet separately.
In case of continuous cast billets and billets produced from ingots of masses 3 tonnes and more, the
sample may be taken from anywhere from the billets.
Freedom from defects
The billets and continuous cast billets shall be free from harmful defects, such as pipe, laminations,
segregation, inclusions and cracks.
Subject to agreement between the purchaser and the manufacturer, the billets and continuous cast
billets may be supplied with suitable surface dressing.
billets shall either be supplied free from harmful segregation, piping, cracks, inclusions, and blow-
hole by appropriate top and bottom discard and dressing or supplied with suitable surface dressing
only, without top and bottom discard if agreed to between the purchaser and the manufacturer, to
ensure the requirements of freedom from defects specified in the relevant product specifications.
If agreed to between the purchaser and the manufacturer the following tests may be carried out
from the samples prepared under IS: 8056-1976
Dimensions
The size and tolerance of billets shall be subject to agreement between the purchaser and the
manufacturer. However, the nominal sizes of billets generally supplied as per guidance given in IS:
8056-1976
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The preferred sizes of billets shall be 50, 63, 71, 80, 90, 100 and 125 mm.
The sizes other than those specified may be supplied by agreement between the purchaser and the
manufacturer.
A tolerance of the billets shall be confirmed with IS: 8056-1976

The ends of ingots and billets shall be painted with a suitable colour code conforming to IS: 2049-
1963.
Each ingot and billet shall be legibly stamped or painted with the cast number, grade and the name
or trade-mark of the manufacturer.
The material may also be marked with the IS1 Certification Mark.
All steel for reinforcement shall be clean and free from loose mill scales, dust, loose rust, oil, grease,
paint or other harmful matters, which may affect its bond with concrete. Mild steel and medium
tensile steel bars and hard drawn steel wire for concrete reinforcement shall conform to grade-1 of
IS:432 (Part-1). High strength deformed steel bars shall conform to grade Fe 415 of IS:1786. All
steel bars shall be of tested quality. Actual grade and type steel, to be used, shall be as specified or
shown on drawings.
Structural steel (including embedded steel) shall be straight, sound, free from twists, cracks, flaws,
laminations and all other defects. Structural steel shall be of tested quality conforming to IS:226,
IS:2062 or IS:8500. These shall be free from lamination defects. Grade and type of steel to be used
shall be as specified.
Hard drawn steel wire fabric shall conform to IS:1566. Wire fabric shall be electrically cross
welded.
2.13 Storage and handling of materials
Generally, all materials shall be stacked and stored by the Concessionaire as described in IS:4082
unless otherwise mentioned and in a manner affording convenient access for identification and
inspection at all times. The storage area and arrangements shall be subject to the approval of the
Project Engineer and Executing Agency. Any material rendered unserviceable during the
Concessionaire’s custody, shall be replaced or repaired by the Concessionaire as determined by the
All materials shall be as stored as to prevent deterioration or intrusion of foreign matter and to
ensure the preservation of their quality and fitness for the work. Any material, which has
deteriorated or has been damaged or is otherwise considered defective by the Project Engineer and
Executing Agency, shall not be used and shall be removed.
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Bricks shall not be dumped at site. These shall be stacked on dry firm ground in regular tiers even
as they are unloaded to minimize breakage and defacement of bricks. Bricks of different class,
selected for various categories of use in the work, shall be stacked separately. Each stack shall
contain equal number of bricks, preferably not more than 3000.
Dressed stone for all facing, paving etc. shall be stored with special care to avoid defacement of
faces and edges or damp and rust stains.
Lime shall be stored in weather-proof sheds. Lime which has been damaged by rain, moisture or
air slaking, shall not be used. If the lime is supplied as hydrated lime, it shall be stored in the same
manner as cement.
2.13.1 Cement and fly ash
a. Consignments of cement shall be stored as received and shall be consumed in the order of
their delivery. Cement held in storage for more than ninety days shall invariably be tested,
and only if test results are satisfactory, the Project Engineer and Executing Agency may
consider permitting its use.
b. Different consignments of different types of cement, i.e. OPC, PPC, PSC shall be stacked
separately with clear identifiable stack number.
c. The cement shall be stored in dry, leak proof and weather proof are closed sheds. Storage
under tarpaulins shall not be permitted. The cement bags shall be stored well away from the
walls and insulated from the floor, usingPlanks etc. to avoid contact with moisture. The
cement shall be stacked in easily countable stacks and in a place of easy access so as to
facilitate proper inspection and removal on a first in first out basis. Not more than 15 bags
shall be stacked in any tier to prevent lumping up under pressure. However, in stacks more
than 8 bags high, the cement bags shall be arranged alternately lengthwise and crosswise so
as to tie the stacks together and minimize the danger of toppling over. The cement bags shall
be gently kept to avoid leakage of cement from the bags. Substandard or partially set cement
shall be immediately removed from the site as soon as it is detected.
d. The Concessionaire shall make his own arrangements for the storage of adequate quantity of
cement. Cement in bulk may be stored in bins or silos which will provide adequate protection
against dampness, contamination, etc. The bins or silos, shall be cleaned periodically.
e. Pulverized fuel ash (Fly ash) shall be stored in accordance with the recommendation given
in IS 4082. Additionally, during bulk storage, the fly ash should be suitably covered to avoid
getting airborne.
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f. Supplies of pulverized fuel ash (Fly ash) may be made in bulk in suitable quantities or in
bags (jute, jute-laminated, multiple paper or polyethylene lined) bearing the net mass (may
be 15 kg, 30 kg, 300 kg, 600 kg as agreed by the Concessionaire)
g. Pulverized fuel ash in bulk storage for more than 6 months or in bags for more than-3 months
after completion of tests, may be re-tested before use and standard. May be rejected, if it fails
to conform to any requirements of this standard.
h. Pulverized fuel ash may be rejected if it does not comply with any of the requirements
stipulated in IS 3812 Part 2 of 2003
2.13.2 Coarse and fine aggregates/sand
a. Coarse and fine aggregates shall be stacked separately. Contamination with foreign materials
and earth during storage and while heaping the materials shall be avoided. Coarse aggregates
shall be stacked in layers not exceeding 120 cm in height such that corning and segregation
do not occur. Each layer shall cover the entire area of the stock pile before succeeding layers
are placed. Segregated aggregates from stock-pile shall be rejected.
b. Aggregates shall be stored on brick soling or an equivalent platform so that they do not come
in contact with dirt, clay, grass or any other injurious substance, at any stage. For lifting
aggregates from stock piles, rakers shall be used. Aggregates of different sizes shall be kept
in separate and easily measurable stacks. If so desired by the Project Engineer and Executing
Agency, aggregates from different source shall be stacked separately with proper care to
prevent intermixing.
2.13.3 Reinforcement and Structural Steel (including steel required for embedment)
a. Reinforcement and structural steel (including steel required for embedment) shall be stored
consignment wise and size wise, off the ground by at least 150mm and protected by the
suitable cover, or as desired by the Project Engineer and Executing Agency. The steel shall
be protected from rusting, oil grese and distortions. The reinforcing steel shall be coated with
cement wash before stacking to prevent scale and rust, in areas having accelerating corrosion
effect like marine atmosphere. The stacks shall be easily measurable. Steel needed for
immediate use only shall be removed from storage. Fabricated steel shall be carefully stored
to prevent damage, distortion, corrosion and deterioration.
b. Reinforcement shall be stored according to the diameter, grade and length in such a place as
to permit easy approach for inspection and identification.
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c. The area shall be such that water does not accumulate and reinforcement does not get
distorted or corroded. It shall not be stacked directly over ground or near any harmful
materials. It shall be cleaned of excessive rust before use.
d. Steel plates of different specifications shall be stacked separately. Steel of IS:2062 and
IS:8500 quality shall be given a grade wise, distinctive identification mark. Passage and space
between the stacks shall be sufficient for rigging operations.
2.14 Testing
All materials provided by the Concessionaire shall be tested for conformity of the specification and
the test results shall be submitted to the Project Engineer and Executing Agency for acceptance. In
addition to above, the Concessionaire shall carry out the relevant tests at site as specified under
different items of work.
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Sub-section - C3
Technical specification for cast-in-situ concrete AND allied works
150
Sub Section - C3
Technical specification for cast-in-situ concrete and allied works
Contents
3.1 Common requirement ................................................................................................................... 152

3.2 Cast-in-situ concrete ..................................................................................................................... 156
3.3 Reinforcement ............................................................................................................................... 175
3.4 Formwork and staging .................................................................................................................. 179
3.5 Embedded parts ............................................................................................................................. 184
3.6 Foundation bolt assembly ............................................................................................................. 185
3.7 Shotcreting .................................................................................................................................... 186
3.8 Grouting ........................................................................................................................................ 188
3.9 Encasement of steel structures / elements ..................................................................................... 191
3.10 Joints in concrete........................................................................................................................... 191
3.11 Waterproofing / damp proofing of underground concrete structures ............................................ 197
3.12 Dismantling / demolishing work - RCC and PCC ........................................................................ 201
3.13 Cement additives / admixtures in concrete ................................................................................... 202
3.14 Slab on grade................................................................................................................................. 206
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Sub Section - C3: Technical specification for cast-in-situ concrete and allied works
Common requirement
3.1.1 Scope
The work shall include providing of materials, all necessary plant and equipment, providing
adequate engineering supervision and technical personnel, skilled and unskilled labour, etc. as
required to carry out the entire work as indicated on the drawings and/or described herein
subsequently and/or as directed by the Project Engineer and Executing Agency.
The Concessionaire shall carry out all works meant within the intent of this specification even if
not explicitly mentioned herein. All works shall be executed to the satisfaction of the Project
Engineer and Executing Agency.
This specification is divided into 13 sections. The Section - 1 deals with common requirements and
the other 12 sections deal with specifications for 12 different items/activities. The stipulations
contained in Section-1, ‘Common Requirements’ shall form a part of the specifications of 12
different items/activities described in section 2 to 13.
All these eight sections are as follows:
Section - 1 Common requirement

Section - 2 Cast-in-Situ Concrete
Section - 3 Reinforcement
Section - 4 Formwork and staging
Section - 5 Embedded parts
Section - 6 Foundation bolt assembly
Section - 7 Shotcreting
Section - 8 Grouting
Section - 9 Encasement of steel structures/elements
Section - 10 Joints in Concrete
Section - 11 Water proofing / damp proofing of underground concrete structures.
Section - 12 Dismantling / Demolishing works - RCC and PCC.
Section - 13 Cement Additives/Admixtures in concrete.
3.1.2 General
Any approval, instructions, permission, checking, review, etc. whatsoever by the Project Engineer
and Executing Agency, shall not relieve the Concessionaire of his responsibility and obligation
regarding adequacy, correctness, completeness, safety strength, quality, workmanship, etc.
positions of all work and establishing the reduced levels (RLs) at these locations, based on two
reference grid lines and one bench mark, which will be furnished by the Executing Agency. The
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Concessionaire has to provide at site, faction of the Engineer so that the work can be carried out
accurately and according to the specifications and drawings.
3.1.3 Codes and standards
All applicable standards, specifications, etc. and codes of practice shall generally be the latest
editions, including all applicable official amendments and revisions. A complete set of all these
documents shall generally be available at site, with the Concessionaire.
All work shall be carried out as per the stipulations contained in various sections of these
specifications and the latest Indian Standards, Acts, Codes and best practices.
In case of conflict between the stipulations contained in various sections of these specifications and
stipulations of Indian Standards, Codes, etc. the requirements of stipulations contained in various
sections of these specifications, shall prevail over that of Indian Standards, Codes, etc.
Some of the applicable Indian Standards, Codes, etc. are referred to here below:
IS:73 - Specification for paving bitumen

IS:2062 - Specification for structural steel
IS:269 - Specification for Ordinary Portland cement, 33 grade.
IS:280 - Specification of mild steel wire for general engineering purposes
IS:383 - Specification for coarse and fine aggregates from natural sources for concrete.
IS:432 - Specification for mild steel and medium tensile steel (parts I & II) bars and hard
drawn steel wire for concrete reinforcement.
IS:455 - Specification for Portland slag cement
IS:456 - Code of practice for plain and reinforced concrete.
IS:457 - Code of general construction of plain & reinforced concrete for dams & other
massive structures.
IS:516 - Method of test for strength of concrete
IS:650 - Specification for standard sand for testing of cement
IS:702 - Specification for industrial bitumen
IS:816 - Code of practice for use of metal arc welding for general construction in mild
steel.
IS:1199 - Method of sampling and analysis of concrete
IS:1200 - Method of measurement of building (Part-II and civil engineering works. V, VIII,
XVIII)
IS:1367 - Technical supply conditions for threaded steel fasteners.
IS:1489 - Specification for Portland-pozzolana cement (Part-I) Fly ash based (Part-II)
Calcined clay based
IS:1566 - Specification for Hard-drawn steel wire fabric for concrete reinforcement.
IS:1609 - Code of practice for laying damp proof treatment using bitumen felts.
S:1786 - Specification for high strength deformed steel bars and wires for concrete
reinforcement
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IS:1791 - General requirements for batch type concrete mixers.
IS:1838 - (Part 1) Specification for preformed fillers for expansion joints in concrete
pavements and structures (non extruding and resilient type)
IS:2204 - Code of practice for construction of reinforced concrete shell roof.
IS:2210 - Criteria for the design of reinforced concrete shell structures and folded plates.
IS:2386 - Methods of test of aggregates for (Parts concrete I to VIII)
IS:2438 - Specification for roller pan mixer
IS:2502 - Code of practice for bending and fixing of bars for concrete reinforcement
IS:2505 - General requirements for concrete vibrators, immersion type.
IS:2506 - General requirements for concrete vibrators, screed board type.
IS:2514 - Specification for concrete vibrating tables.
I:2571 - Code of practice for laying in-situ cement-concrete flooring.
IS:2645 - Specification for Integral cement water proofing compounds.
IS:2722 - Specification for portable swing weigh batchers for concrete. (Single and double
bucket type)
IS:2750 - Specification for Steel scaffoldings
IS:2751 - Code of practice for welding of mild steel plain and deformed bars for reinforced
concrete structures.
IS:3025 - Methods of sampling and test waste water.
IS:3067 - Code of practice for general design details and preparatory work for damp
proofing & water proofing of buildings.
IS:3150 - Specification for hexagonal wire netting for general purposes.
IS:3366 - Specification for Pan vibrators.
IS:3370 - Code of practice for concrete (Part I structures for the storage of to IV) liquids.)
IS:3384 - Specification for bitumen primer for use in water proofing & damp proofing.
IS:3414 - Code of practice for design and installation of joints in buildings.
IS:3550 - Methods of test for routine control for water used in industry
IS:3558 - Code of practice for use of immersion vibrators for consolidating concrete.
IS:3696 - Safety code for scaffolds (Part I ladders & II)
IS:3812-2 - Specification for pulverized fuel ash for use as admixture in cement mortar and
concrete
IS:4014 - Code of practice for steel tubular scaffolding (Parts I & II)
IS:4031 - Methods for physical tests for hydraulic cement.
IS:4130 - Safety Code for demolition of buildings.
IS:4326 - Code of practice for earthquake resistant design and construction of buildings.
IS:4461 - Code of practice for joints in surface hydro-electric power stations.
IS:4656 - Specification for form vibrators for concrete.
IS:4925 - Specification for batching and mixing plant.
IS:4990 - Specification for plywood for concrete shuttering work.
IS:4995 - Criteria for design of reinforced concrete bins for the storage of granular and
powdery materials. (Parts I & II)
IS:5121 - Safety code for piling and other deep foundations.
IS:5256 - Code or practice for sealing joints in concrete lining on canals.
IS:5525 - Recommendations for detailing of reinforcement in reinforced concrete work.
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IS:5624 - Specification for foundation bolts.
IS:6461 - Glossary of terms relating to cement concrete.
IS:6494 - Code of practice for water proofing of underground water reservoirs and
swimming pools.
IS:6509 - Code of practice for installation of joints in concrete pavements.
IS:7193 - Specification for glass fiber base coal-tar pitch and bitumen felts.
IS:7293 - Safety code for working with construction machinery.
IS:7861 - Code of practice for extreme weather concreting (Parts I&II)
IS:9012 - Recommended practice for Shotcreting.
IS:9103 - Specification for admixtures for concrete.
IS:9417 - Recommendations for welding cold-worked steel bars for reinforced concrete
construction.
IS:959 - Recommendations for metal-arc welding of carbon and carbon manganese steels.
IS:10262 - Recommended guidelines for concrete mix design.
IS:11384 - Code of practice for composite construction in structural steel and concrete.
IS:12118 - Specification for two-parts poly sulphide.
IS:12200 - Code of practice for provision of water stops at transverse contraction joints in
masonry and concrete dams.
IS:12269 - 43/53 Grade ordinary Portland cement.
IS:12600 - Portland cement, low heat.
SP:23 - Handbook of concrete mixes
SP:24 - Explanatory Handbook on IS:456-1978
SP:34 - Handbook on concrete reinforcement and detailing
3.1.4 Sampling, testing and quality assurance
Facilities required for sampling materials, concrete, reinforcement, formwork, etc. in the field and
in the laboratory shall be provided by the Concessionaire. The Concessionaire shall carry out all
sampling and testing in accordance with the relevant Indian Standards and/or International
Standards and this specification. Where no specific testing procedure is mentioned, the tests shall
be carried out as per the prevalent accepted engineering practice to the directions of the Project
Engineer and Executing Agency. Tests shall be done in the field in the presence of the Project
Engineer and Executing Agency or his authorized representative and at a laboratory, approved by
the Project Engineer and Executing Agency, and the Concessionaire shall submit to the Project
Engineer and Executing Agency the test results in triplicate within three days after completion of
any test.
The Concessionaire shall maintain records of all inspection and testing, which shall be made
available to the Project Engineer and Executing Agency. The Project Engineer and Executing
Agency at his discretion, may waive some of the stipulations for small and unimportant concreting
operations and other works.
Work found unsuitable for acceptance shall be removed and replaced by the Concessionaire. The
work shall be redone as per specification requirements and to the satisfaction of the Project
Engineer and Executing Agency at no extra cost to the Executing Agency.
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Quality assurance program
a) The Concessionaire shall submit and finalize a detailed field Quality Assurance Program
within 30 days from the date of award of the contract, before commencement of work at site,
according to the requirements of the specification. This shall include setting up of a testing
laboratory, arrangement of testing apparatus / equipment, deployment of
qualified/experienced manpower, preparation of format for record, field quality plan, etc. On
finalized field quality plan, the Executing Agency shall identify, customer hold points,
beyond which work shall not proceed without written approval from the Project Engineer.
The testing apparatus/equipment installed in the field laboratory shall be calibrated /corrected
by the authorized persons as frequently as possible to give accurate testing results.
b) Frequency of sampling and testing, etc. and Acceptance Criteria are given in respective
sections. However, the testing frequencies set forth are the desirable minimum and the
Project Engineer and Executing Agency shall have the full authority to carry out or call for
tests as frequently as he may deem necessary to satisfy himself that the materials and works
comply with the appropriate specifications.
Cast-in-situ concrete
3.1.5 Scope
This section of the specification deals with plain or reinforced cement concrete for general use and
in structures and covers the requirements for concrete, materials, their properties, storage, handling,
grading, mix design, strength and quality, pouring at all levels, testing, casting, protecting, curing,
finishing, etc.
3.1.6 General requirement
The provision of IS:456 (as per latest amendment) shall be followed as general guidance, along
with all other relevant Indian Standards, unless otherwise specifically mentioned.
Before starting a concrete pour, the Concessionaire shall obtain the approval of the Project Engineer
and Executing Agency on a ‘Pour Card’ maintained for this purpose. He shall obtain complete
instructions about the materials and proportions, water cement ratio, etc. to be used,
slump/workability, number of test cubes/samples to be taken, type of finishing to done, any
admixture to be added, any limitation on size of pour and location for interruption of a pour in case
of premature stopping of pour, etc.
The mixers and weigh-batchers, shall be maintained in clean and serviceable condition. Accuracy
of all equipment shall be periodically checked. All concrete shall be mixed in mechanically
operated batch mixers complying with IS:1791 and these shall be of approved make, with suitable
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provision for correctly controlling the water delivered to the drum. Weigh batchers shall conform
to IS:2722 and shall be capable of controlling the weights to within one percent of the desired value.
The Concessionaire’s procedures for casting massive concrete sections (as noted on the drawings
or as identified by the Project Engineer and Executing Agency) shall take account of the release of
the heat of hydration, drying shrinkage behavior. The procedures shall be such that cracking or loss
of strength of the concrete from these effects is prevented. At least one week before commencing
the construction of any massive concrete section, the Concessionaire shall submit, for approval of
the Project Engineer and Executing Agency, detailed proposals for placing the concrete together
with supporting calculations to demonstrate the suitability of the methods.
3.1.7 Materials
In general, all the materials used in the manufacture of concrete shall be in accordance with the
Technical specification for properties, storage and handling of common building materials, (vide
module C2) which shall be deemed to form a part of this specification.
The Project Engineer and Executing Agency shall have the right to inspect the sources of materials,
method of procurement and storage of materials, method of procurement and storage of materials,
quality control procedures, etc.
 Cement
The cement used shall be the Ordinary Portland cement conforming to IS: 269 or Portland
Pozzolana cement conforming to IS: 1489 or Portland slag cement conforming to IS: 455 or any
other type of cement specified in IS: 456 with the prior approval of the Project Engineer and
Executing Agency. However, any special type of cement such as High strength cement or sulphate
resisting cement may be used under special circumstances.
 Aggregates
a) For reinforced concrete work, aggregates conforming to IS: 383 & IS: 2386 having a
maximum size of 20 mm shall be used. For certain reinforced concrete works, aggregates
having a maximum size other than 20 mm size shall also be used as called for in the drawings.
However, for lean concrete provided as mud mat below structural concrete, maximum size
upto 40 mm shall be used.
b) Aggregates (coarse or fine) with a specific gravity below 2.6 shall not be used without special
permission of the Project Engineer and Executing Agency. Machine-made sand will be
acceptable provided the constituent (rock/gravel) is sound, hard, dense and is acceptable to
the Project Engineer and Executing Agency. Sand, natural gravel and crushed rock shall be
prepared for use by such screening or washing, or both, as necessary to remove all
objectionable foreign matter.
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c) Type of aggregates: Petro graphic examination shall be carried out to ascertain the structure
and rock type of aggregate including presence of strained quartz and other reactive minerals.
Moreover, in case the coarse aggregate sample is of composite nature, the proportions (by
weight) of different rock types in the composite sample and petrographic evaluation of each
rock should also be ascertained. While determining different rock type is in the composite
sample, special emphasis should be given on identification of known reactive rocks like
chalcedony, opal etc. and procedure laid down in IS:2430 for sampling of aggregates may be
followed. The sample should not contain weathered rock and reduced to required quantity by
quartering and coning.
The results of petro graphic test shall be submitted to the Project Engineer and Executing
Agency. The Project Engineer and Executing Agency shall review the results on consultation
with some specialist agencies, if required, to determine potential activity of the aggregate
(siliceous minerals) which may lead to reaction of silica in aggregate with the alkalis of
cement. In additional, potential of some aggregate like lime stone to residual expansion due
to repeated temperature cycle is also to be reviewed. Further, the Concessionaire shall submit
the results of Alkali aggregates reactivity carried out as per IS: 2386 (Pt. VII).
In case of any apprehension about the properties of the aggregate, the Project Engineer and
Executing Agency shall ask the Concessionaire to send samples of coarse and fine aggregate
to any of the established research laboratory including National Council for Cement and
Building Materials (NCB).
In case, it is established from the tests that the aggregates contain reactive silica which would
react with alkalis of the cement, the Concessionaire shall be asked to change the source of
supply of the aggregate and take additional measures as suggested. In case aggregates
indicate residual expansion, under repeated temperature cycle test, the material shall not be
used for concreting of equipment foundations, which are likely to be subjected under repeated
temperature cycle. The Concessionaire shall use different type of aggregate as approved by
the Project Engineer and Executing Agency.
 Admixtures
Admixtures in concrete for promoting workability, improving strength, entraining air for similar
purposes may be used only after the written permission from the Project Engineer and Executing
Agency is obtained. These shall be free from injurious amount of chloride, etc. Addition of
admixtures should not reduce the specified strength or durability of concrete and should not have
detrimental effect on reinforcement. The admixtures shall conform to IS:9103 and shall be of
proven make and from a reputed manufacturer. Calcium chloride as accelerating admixture is not
permitted to be used other than in mass concrete works. The Concessionaire shall produce latest
test results carried out at approved Government Test Houses for the approval of the Project
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3.1.8 Water
Water used for mixing and curing shall be clean and free from injurious amounts of oils, acids,
alkalis, sugar, organic materials or other substances that may be deleterious to concrete or steel.
Potable water is generally considered satisfactory for mixing concrete. The maximum permissible
values of impurities shall be as given in Clause no. 4.3 of IS:456-1978.
In case of doubt regarding development of strength, the suitability of water for making concrete
shall be ascertained by the compressive strength and initial setting time tests specified in IS:456.
Average 28 days compressive strength of atleast three 150 mm concrete cubes prepared with water
proposed to be used shall not be less than 90% of the average strength of three similar concrete
cubes prepared with distilled water. The cubes shall be prepared, cured and tested in accordance
with IS:456.
The initial setting time of a concrete test block made with the appropriate cement and the water
proposed to be used shall not be less than 30 minutes and shall not differ by + 30 minutes from the
initial setting time of control test block prepared with the same cement and distilled water. The test
shall be carried out as per IS:4031.
Where concrete, made from water, proposed to be used does not satisfy the above requirements
and/or contains an excess of acid, alkali, sugar, salt or other deleterious, substances, then the Project
Engineer and Executing Agency may refuse to permit its use. Sea water shall not be used for curing
besides mixing in concrete.
3.1.9 Grades of concrete
All concrete shall be “design mix concrete” as defined in IS: 456, unless an nominal mix concrete
such as 1:2:4, 1:3:6, 1:4:8 of 1:5:10 proportion is specified. The proportion referred to is by weight
(mass). The grades for ‘design mix’ concrete shall be designated M-15, M-20, etc. as specified in
IS: 456. (20% replacement ratio of cement with fly ash shall be considered):
 Nominal mix concrete
a) Nominal mix concrete shall be used only for plain Cement concrete works and where shown
on drawings or specifically allowed by the Project Engineer and Executing Agency. Such
concrete shall not require preparation of trial mixes and all such concrete shall be mixed in a
mechanical mixer. Proportions for nominal mix concrete shall be according to Table-3 of IS:
456-1978. In addition, standard proportion by volume shall be used wherever specified.
b) In proportioning concrete, the cement & fly ash shall be measured by (mass) weight. The
quantities of fine and coarse aggregates may be determined by volume (for corresponding
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weight) but preferably by weight. If fine aggregates are moist, the amount of surface water
shall be determined. Also an allowance shall be made for bulking in case of volume batching,
in accordance with IS:2386 (Part-III). Allowance shall also be made for surface water present
in the aggregates, when computing the water requirement. All the above data shall be
maintained properly, to the satisfaction of the Project Engineer and Executing Agency.
c) The recommended maximum water cement ratios are specified in Table 1.
Table 1: Recommended water - Cement ratio

Nominal mix concrete Quantity of water per 50 Kg. of cement (max.)
1:5:10 60 litres
1:4:8 45 litres
1:3:6 34 litres
1:2:4 32 litres
d) Nominal mix concrete 1:5:10 shall correspond to grade M5, 1:4:8 shall correspond to grade
M7.5, 1:3:6 to grade M10 and 1:2:4 to grade M15 of IS: 456.
e) If Nominal mix concrete made in accordance with specified proportions does not yield the
specified strength of the corresponding grade and fails to satisfy the requirements of
“acceptance criteria for concrete” as specified in IS: 456. Such concrete shall be treated in
the following manner:
i) In case the Project Engineer and Executing Agency is satisfied that lower strength of
concrete is attributed to material and workmanship of the Concessionaire, then such
concrete shall be replaced by concrete of specified strength. The Project Engineer and
Executing Agency may however, also accept such lower strength concrete but such lower
strength concrete shall be classified as belonging to the appropriate lower grade
proportion.
ii) In case the Project Engineer and Executing Agency is satisfied that lower strength of
concrete is not attributable to the Concessionaire, he may direct in writing to increase the
cement content to obtain specified strength. The use of richer mix shall be continued until
the Project Engineer and Executing Agency instructs otherwise.
f) Nominal mix proportion shall not be classified as higher grade proportion either on the
ground that the test strengths are higher than the minimum specified or in the case where
the Project Engineer and Executing Agency directs use of additional cement over the
quantity specified for the particular mix proportion to achieve the minimum specified
strength.
 Design mix concrete
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a) Design mix concrete shall be used on all concrete works, except where specified otherwise
or specially permitted by the Project Engineer and Executing Agency. The mix shall be
designed for all grades of concrete (except those specified under Nominal Mix Concrete
(20% replacement ratio of cement with fly ash):) such as to obtain for works cubes, the
required workability and the characteristic strength not less than the appropriate values given
in Table 2. Using Standard Deviation specified in IS:10262 corresponding to good quality
control, the Minimum value of target strength of design mix of various grades of concrete
shall be as per Table 2.
However, the Project Engineer and Executing Agency may allow to change the target
strength values based on adequate numbers of works test results.
Table 2: Grades of concrete

Compressive strength of a 15 cm cube at 28 days (N/Sq.mm)
Grade designation of Preliminary test strength Characteristic strength on
concrete (target of trial mix) strength works cubes
M 15 20.8 15
M 20 27.6 20
M 25 33.7 25
M 30 39.9 30
M 35 45.4 35
b) In proportioning concrete, the quantity of cement, fly ash and aggregates shall be determined
by mass. However, only in some exceptional cases including concreting in some isolated
areas, the Project Engineer and Executing Agency may allow the quantity of aggregates to
be determined by an equivalent volume basis after the relationship between weight and
volume is well established by trials and the same shall be verified frequently. Water shall be
either measured by volume in calibrated tanks or weighed. All measuring equipment at site,
shall be maintained in a clean and serviceable condition, and their accuracy shall be
periodically checked.
c) To keep the water-cement ratio to the designed value, allowance shall be made for the
moisture contents in both fine and coarse aggregates and determination of the same in
accordance with IS:2386 Part (III) shall be made as frequently as directed by the Project
In some of the structures, water-cement ratio shall be restricted even below 0.45. To increase
the workability, plasticizer may have to be used in such cases. Trial mix shall be carried out
accordingly.
d) With the permission of the Project Engineer and Executing Agency, for any of the above
mentioned grades of concrete, if the water quantity has to be increased, proportionately
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cement quantity shall also be increased, to keep the ratio of water to cement same as adopted
in Preliminary tests for the corresponding grade of concrete. The extra cement required on
account of this shall also be considered for reconciliation purposes.
 Mix design
a) IS:10262 shall be followed as general guidance for mix design. Preliminary tests/trial mix,
as specified or as required by the Project Engineer and Executing Agency, shall be carried
out sufficiently ahead of the actual commencement of the work with different grades of
concrete made from representative samples of aggregates and cement & fly ash expected to
be used on the works. These tests are to be conducted to arrive at the grading of aggregates,
water cement ratio, workability and the quantity of cement required to give Preliminary
(target) compressive strengths as specified in Table - 2.
b) Minimum cement contents, from durability consideration, or different exposures and

sulphate attack shall be as given in Table - 19 and 20 of IS: 456. In case, higher value is
obtained from trial mix from strength consideration, same shall be considered.
c) At least four trial mixes are to be made and minimum. Six test cubes taken for each trial mix
noting the slump for each type of mix. The cubes shall then be properly cured and three cubes
for each mix shall be tested in a laboratory (approved by the Project Engineer and Executing
Agency) at 7 days and others at 28 days and others at 28 days for obtaining the compressive
strength. The test reports shall be submitted to the Project Engineer and Executing Agency.
The design mix particulars shall indicate, with the help of graphs and curves etc. the extent
of variation in the grading of aggregates which can be allowed. While designing mixes, over
wet mixes shall be avoided. For chimney, natural draft cooling tower, etc. where assessment
of early strength is required, the concrete cubes shall also be tested for early age strength at
1 day and 3 days for establishing the values.
d) The Concessionaire shall submit the test reports of mix design to the Project Engineer and
Executing Agency for his view, indicating design criteria, analysis and proportioning of
materials, etc. On the basis of the above test reports, a mix proportion by mass and the water
cement ratio, shall be determined by the Concessionaire such that concrete prepared with this
mix yield the desired characteristic strength and shall have suitable workability. The mix
design to be adopted on the works shall be subject to the approval of the Project Engineer
and Executing Agency. The proportions, once decided for different grades of concrete, shall
be adhered to, during all concreting operations as long as the quality of the materials does
not change. If, however, at any time, the quality of materials being used has changed from
those for Preliminary mix design, or there is a change either in the required strength of
concrete, or water cement ratio or workability, the Concessionaire shall have to make similar
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trial mixes and Preliminary tests to ascertain the revised mix proportions and water cement
ratio to be used for obtaining the desired strength and consistency.
e) In the situations, like casting of piles, where the compaction of concrete is not possible by
vibration, the method of compacting concrete cubes of Preliminary / trial mixes and work
tests shall be in the same manner as the method of compacting concrete at site is proposed.
 Workability of concrete
a) The workability of concrete shall be checked at frequent intervals. The workability of

concrete measured in accordance with IS:1199 for every sample taken for testing shall be
recorded with the corresponding cube test result.
b) The degree of workability necessary to allow the concrete to be well compacted and to be
worked into the corners of formwork and round the reinforcement to give the required surface
finish shall depend on the type and nature of the structure and shall be based on experience
and tests. The suggested ranges of values of workability for concrete for some placing
conditions, measured in accordance with IS:1199 as stipulated under Clause No. 6.0 of
IS:456, are given below in Table - 3, for guidance only. In addition, in some special cases
like casting of pile, very high degree of workability (up to 180 mm slump) shall be used.
Table 3: Limits of workability

Placing Degree of workability Value of workability
Concreting of shallow sections Very low 20-10 seconds, Vee-bee time

with vibration factor or
0.75-0.80 compacting.
Concreting of lightly reinforced Low 10-5 seconds, Vee-bee time

section with vibration or
0.80-0.85 compacting factor.
Concreting of lightly reinforced Medium 5-2 seconds, Vee-bee time
section without vibration, or or
heavily reinforced sections with 0.85-0.92 compacting factor
vibration or
25-75mm, slump for 20 mm
aggregate (for smaller aggregate
the values will be lower).
High Above 0.92 compacting factor

Concreting of heavily reinforced or
sections without vibration
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75-125 mm slump for 20 mm
aggregate (for smaller aggregate
the values will be lower)
Note: Notwithstanding the values given above, the slump to be maintained for work in progress shall be
as per directions of the Project Engineer and Executing Agency.
 Mixing of concrete
a) Concrete shall be mixed in a mechanical mixer conforming to IS: 1791. However, mixing
shall preferably be done at a single central batching plant, conforming to IS: 4925, situated
within the area allocated for the Concessionaire’s particular use as shown on the drawing or
as directed by the Project Engineer and Executing Agency. The plant shall have a
mechanically operated mixer of an approved size and type, capable of ensuring a uniform
distribution of the materials throughout the mass and the mass is uniform in colour and
consistency.
b) Water shall not be added into the drum of the mixer, until all the cement and aggregates
constituting the batch are already in the drum and dry mixed for at least one minute and are
uniformly distributed. Water shall then be added and mixing of each batch shall be continued
until there is a uniform distribution of the materials and the mass but in no case shall mixing
be done for less than two minutes and for atleast 40 revolutions after all the water and
materials are in the drum. When absorbent aggregates are used or when the mix is very dry,
the mixing time shall be extended as directed by the Project Engineer and Executing Agency.
Mixers shall not be loaded above their rated capacity as this prevents thorough mixing.
c) The entire contents of the drum shall be discharged before the ingredients for the next batch
are fed into the drum. No partly set or remixed or excessively wet concrete shall be used and
it shall be immediately removed from site. Each time if the work stops for more than 30
minutes, the mixer shall be thoroughly cleaned and when the next mixing commences, the
first batch shall have 10% additional cement.
d) In exceptional circumstances and/or work in remote areas, hand mixing may be allowed by
the Project Engineer and Executing Agency, subject to adding 10% extra cement which shall
be considered for reconciliation purposes. The mixing shall be carried out on watertight
platform and mixing shall be continued till a uniform colour and consistency of the mix is
achieved.
 Concrete conveying
a) Concrete shall be handled and conveyed as rapidly as practicable, from the place of mixing
to the place of final laying, by approved means, before the initial setting of the cement starts.
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Concrete shall be conveyed in such a way that there is no segregation or loss of any of the
ingredients and maintaining the required workability. If segregation does occur during
transport, the concrete shall be remixed.
During very hot or cold weather, if directed by the Project Engineer and Executing Agency,
concrete shall be transported in deep containers, which will reduce the rate of water loss by
evaporation in hot weather and heat loss in cold weather, at no extra cost to the Executing
Agency.
b) Conveying equipment for concrete shall be mortar tight, well maintained and thoroughly
cleaned before commencement of concrete mixing. Such equipment shall be kept free from
set concrete. Chutes shall not be used for transport of concrete without the written permission
of the Project Engineer and Executing Agency. The chute in case permitted to be used shall
be of such size and design as to ensure practically continuous flow. Slope of the chute shall
be so adjusted that the concrete flow without the use of an excessive quantity of water and
without segregation of its ingredients. The delivery end of the chute shall be as close as
possible to the point of deposit.
c) Concrete may be conveyed and places by mechanically operated equipment, e.g. pumps or
pneumatic placers only with the written permission of the Project Engineer and Executing
Agency, who shall also review the entire scheme for which comprehensive details shall be
furnished by the Concessionaire.
 Concrete placing
a) Concrete shall be placed and compacted in its final position before the cement reaches the
initial set and normally concrete shall be compacted in its final position within minutes of
leaving the mixer.
b) Where direct placement is not possible, the Concessionaire shall provide suitable
arrangements such as chutes, tremie, elephant trunks, etc. to confine the movement of
concrete as directed by the Project Engineer and Executing Agency. Concrete shall not be
dropped from a height or handled in a manner which may cause segregation.
c) If concrete is placed by pumping, the consistency shall be the minimum necessary for such
conveyance of concrete. Before commencement of regular pumping, the pipeline shall be
lubricated by cement mortar (1:2), and once pumping commences, stoppages shall be
avoided.
d) Concrete shall not be placed in foundations on soft areas or where there is standing water or
debris. Such soft areas shall be removed and filled with 1:4:8/1:3:6 nominal mix concrete, as
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For rock surfaces, it shall be ensured that the rock is not unsound. On sloping rock faces,
rough steps or benches shall be formed and concrete shall not be placed on a sloping rock
surface. Prior to pouring concrete, the rock surface shall be cleaned with a high pressure
water and air jet and kept wet for three hours. Also, before placing concrete, water shall be
removed from depressions, the rock surface shall be dried and a 10mm thick cement sand
mortar (1:6) layer shall be placed and worked into all crevices, cracks, depression, etc.
e) The placing of concrete shall be a continuous operation with no interruption in excess of 30

minutes between the placing of continuous portions of concrete. Concrete shall be placed in
continuous horizontal layers of 150 mm or higher thickness as directed by the Project
Engineer and Executing Agency and thoroughly compacted before placing next layer. The
thickness of each layer shall be such that it will be deposited before the previous layer has
stiffened. When placing concrete through reinforcing steel, care shall be taken to prevent
segregation of the coarse aggregates.
f) Approval by the Project Engineer and Executing Agency of any of the materials and/or work
as required herein shall not relieve the Concessionaire of his obligation to produce finished
concrete in accordance with the drawings and specifications. Slots, openings, holes, pockets,
etc. shall be provided in the concrete as directed by the Project Engineer and Executing
Agency.
g) Slabs, beams and similar members shall normally be poured in one operation. In special
circumstances, with the approval of the Project Engineer and Executing Agency, these can
be poured in horizontal layers, but it must be ensured that the under layer is not already
hardened. Bleeding of under layer, if any, shall be effectively removed. Molding, throating,
drip course, etc. shall be poured as shown on the drawings or as desired by the Project
h) After the concrete has been placed, it shall be spaded and thoroughly compacted by approved
mechanical vibrators to a maximum subsidence without segregation and thoroughly worked
around reinforcement or other embedded fixtures into the correct form and shape. Hand
tamping in some cases may be allowed subject to the approval of the Project Engineer and
Executing Agency. Care must be taken to ensure that the inserts, fixtures, reinforcement and
formwork are not displaced or disturbed during placing of concrete.
i) Whenever vibration has to be applied externally, the design of formwork and the disposition
of vibrators shall receive special consideration to ensure efficient compaction and to avoid
surface blemishes. Surface vibrators and form attached vibrator shall not be permitted under
normal conditions. Their use shall require written approval of the Project Engineer and
Executing Agency.
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j) Vibrators shall penetrate both the layer poured and the under layer to ensure good bond
homogeneity and to prevent the formation of cold joints. Immersion vibrators shall not be
allowed to come in contact with steel reinforcement after start of initial set. Also, they shall
not be allowed to come in contact with forms or finished surfaces.
k) Immersion vibrators shall have a ‘no load’ frequency, amplitude and acceleration as per
IS:2505 depending upon the size of the vibrator. Immersion vibrators shall be operated by
experienced men. These vibrators shall be immersed not more than 450 mm apart and
withdrawn when air bubbles cease to come to the surface. Such vibrators shall in no case be
used to push concrete inside the forms and vibrators shall be withdrawn slowly.
l) No concrete shall be placed in wet weather or on a water covered surface. If there have been
any signs of washing of cement or sand, the concrete shall be entirely removed immediately.
Suitable precautions shall be taken in advance to guard against possible rains before leaving
the fresh concrete unattended.
m) Mass concrete shall be poured in lifts not exceeding 1.0 m in height unless otherwise
indicated on drawings or as directed by the Project Engineer and Executing Agency.
Horizontal lift shall not be more than 150 cm in thickness, according to provision of IS: 457.
n) Formwork and reinforcement shall be approved in writing by the Project Engineer and
Executing Agency before concrete is placed. Concrete shall be placed only after all
preparations for casting have been approved by the Project Engineer and Executing Agency
and approval given to proceed with the casting in writing on pour card to be maintained by
the Concessionaire for this purpose
o) Concrete, when deposited, shall have a temperature of not less than 5 degrees Centigrade and
not more than 40 degree Centigrade. When depositing concrete in very hot weather,
precautions shall be taken so that the temperature of wet concrete does not exceed 40 degrees
Centigrade while placing. This shall be achieved by stacking aggregates under the shade and
keeping them moist, starting curing before concrete dries out, etc. However, before mixing /
placing concrete, when the above temperature conditions vary on either side, approval of the
Project Engineer and Executing Agency shall be obtained for the method of execution.
 Protection and curing of concrete
a) Newly place concrete shall be protected by approved means from rain, sun and wind.
Concrete placed below ground level, shall be protected from falling earth, during and after
placing. Concrete placed in ground containing any deleterious substances, shall be kept free
from contact with such ground or with water draining from such ground, during placing of
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concrete and for a period of atleast three days or as otherwise instructed by the Project
b) The ground water around newly poured concrete shall be kept down to an approved level by
pumping or other approved means of drainage. Adequate steps shall be taken to prevent
floatation or flooding. Steps, as approved by the Project Engineer and Executing Agency,
shall be taken to protect immature concrete from damage by debris, excessive loading,
vibration, abrasion, mixing with earth or other deleterious materials, etc. that may impair the
strength and durability of the concrete.
c) As soon as the concrete had hardened sufficiently for the surface not to be marked, it shall
be kept in a damp or wet condition by pounding or by covering with a layer of sacking,
canvas, hessian or similar materials and kept continuously wet for atleast seven days after
final setting. This period may be extended, at the discretion of the Project Engineer and
Executing Agency, upto fourteen days. Curing of horizontal surfaces exposed to drying
winds shall begin immediately after the concrete has hardened. Concrete slabs and floors
shall be cured for the periods mentioned above by flooding with water of minimum 25mm
depth.
d) Approved curing compounds may be used in lieu of moist curing with the permission of the
Project Engineer and Executing Agency. However, such permission may be granted only in
specific cases. Such compounds shall be applied to all exposed surfaces of the concrete, as
soon as possible after the concrete has set.
e) Quantity of water applied shall be such as to prevent erosion of freshly placed concrete.
 Construction joints
a) When work has to be interrupted, the concrete shall be rebated and/or keyed at the joint to
such shape and size as may be required by the Project Engineer and Executing Agency or as
shown on the drawings. All vertical construction joints shall be made with stop boards, which
are rigidly fixed and slotted to allow for the passage of the reinforcing steel. In the case of
water retaining structures, basements, tunnels, etc. water stop of approved material shall be
provided, if so specified on the drawings or as directed by the Project Engineer and Executing
Agency.
b) Construction joints shall be located as shown or described on the drawings. Where it is not
described, the joints shall be in accordance with the following guidelines.
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i) In a column, the joints shall be formed about 75 mm below the lowest soffit of the
beams framing into it, including haunches, if any. In flat slab construction, the joint
shall be 75 mm below the soffit of the column capital.
ii) Concrete in a beam shall be placed throughout without a joint. If unavoidable, the joint
shall be vertical and within the middle-third of the span. When a beam intersects a
girder, the joints in the girder shall be given an offset equal to a distance twice the
width of the beam and additional reinforcement provided for shear. The joints shall be
vertical throughout the full thickness of the concrete member with suitable shear key
wherever shown on the drawing.
iii) A joint in a suspended floor slab shall be vertical at one quarter points of the span and
at right angle of the principal reinforcement.
iv) Construction joints in equipment foundations shall not be provided without specific
concurrence of the Project Engineer and Executing Agency.
v) Vertical construction joints in water retaining structures shall not be permitted unless
shown on the drawings.
However, if the Concessionaire desires any adjustments in the location of construction

joints (to suit site conditions) from those shown on drawings or from those explained
above, he shall obtain prior approval from the Project Engineer and Executing Agency.
c) Before fresh concrete is placed, the cement skin of the partially hardened concrete which was
poured earlier shall be thoroughly removed and the surface made rough and aggregate
exposed, by wire brushing, hacking, water jetting, air jetting or any other method as directed
by the Project Engineer and Executing Agency. The rough surface shall be thoroughly wetted
for about ½ hour and shall be dried and coated with 10 to 15 mm thick layer of 1:1 freshly
mixed cement and sand slurry. Special care shall be taken to see that the first layer of concrete
placed after a construction joint is thoroughly rammed against the existing layer.
d) In forming a joint, concrete shall not be allowed to slope away to a thin edge. The locations
of construction joints shall be planned by the Concessionaire well in advance of pouring and
they will have to be approved by the Project Engineer and Executing Agency. The
Concessionaire’s proposals shall include atleast the location of construction joints, the
sequence of pouring, formwork details and their stripping times.
e) Where the concrete has not fully hardened, all laitance shall be removed by scrubbing the
wet surface with wire or bristle brushes. Care being taken to avoid dislodgement of particles
of aggregates. The surface shall be thoroughly wetted and all free water removed. The surface
shall then be coated with neat cement slurry. On this surface, a layer of concrete not
exceeding 150 mm in thickness shall first be placed shall be well rammed against old work,
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particular attention being to corners and close spots. Work thereafter, shall proceed in the
normal way.
f) For multiple lift work a suitable gap shall be maintained between setting of the earlier placed
concrete and the commencement of concrete pour. After depositing concrete in columns,
piers or walked time gap of minimum 4 hours, preferably 24 hours shall be maintained before
depositing concrete in beams, girders or slabs, supported there in order to avoid cracking due
to settlement.
 Work in extreme weather conditions
During hot weather (atmospheric temperature above 40 degree centigrade) of cold weather
(atmospheric temp at 5 degree centigrade and below) the concreting shall be done as per the
procedures and precautions set out in IS:7868 (Parts I and II).
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 Cleaning and finishing of concrete
a) All concrete surfaces shall have an even and clean finish free from honeycombs, air bubbles,
fins or other blemishes unmarred, reasonable smooth. The formwork joint marks on concrete
work exposed to view shall be rubbed with carborandum stone and defects patched up with
paste of cement sand mortar (1:2) and cured. The finish shall be made to the satisfaction of
the Project Engineer and Executing Agency. Concrete surfaces to be subsequently plastered
or where brickwork is to be built against them, shall be adequately hacked as soon as the
form is stripped off so that proper bond can develop.
b) Immediately after removal of forms, the concrete shall be inspected and defective areas as
pointed out by the Project Engineer and Executing Agency shall be removed partially or
entirely as directed. Holes, left by form bolts, etc. shall be filled-up and made good with
cement sand mortar of approved mix. All superficial defects such as honeycombing, rough
patches, etc. shall be similarly made good. If the defective area is at a vulnerable location,
e.g. at the ends of beams & columns etc then it may be necessary to cut out the member
completely or in part and reconstruct as directed by the Project Engineer and Executing
Agency. If epoxies have to be used, the same shall be subject to the approval of the Project
Engineer and Executing Agency. Poured concrete affected by faulty formwork shall be
removed totally and replaced. If so directed, the Concessionaire shall have to resort to
grouting / shotcreting.
c) A smooth finish shall be obtained with the use of forms having smooth and even surfaces
and edges. Panels and form linings shall be of uniform size and be as large as practicable and
installed with closed joints. Upon removal of forms, the joint marks shall be smoothened off
and all blemishes, projections etc. removed leaving the surfaces reasonably smooth and
unmarred.
d) Where integral cement concrete finish is called for, the surface shall be compacted and then
floated and treated with a straight edge and any high and low spots eliminated. The work
shall be carried out as per IS:2571
3.1.10 Sampling, testing and quality assurance including construction tolerances
 General
a) Concrete cubes for works tests shall be cured under laboratory conditions, except when in
the opinion of the Project Engineer and Executing Agency, extreme weather conditions
prevail at which time, these may require curing under job conditions.
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b) For the purposes of statistical analysis, any substandard cube result, which in the opinion of
the Project Engineer and Executing Agency, is due to improper sampling, molding or testing
shall be discarded and a dummy result shall be substituted. The value of a dummy result
shall be equivalent to the average value of the cubes from the same grade of concrete tested
immediately before and after the discarded result. The number of such substandard cubes
shall not exceed 5%.
c) If the ‘strength’ of the laboratory controlled cubes, for any portion of the concrete work, falls
below the compressive strength specified, the Project Engineer and Executing Agency shall
have the right to order a change in the proportions or the water content for the remaining
portion of the surface.
d) If the ‘strength’ of the works cured test cubes falls below the specified strength, the Project
Engineer and Executing Agency shall have the right to require provisions for temperature
and moisture control during the period of curing as necessary to secure the required strength,
and may require retest in accordance with the standard method of securing, preparing and
testing specimens from hardened concrete for compressive and flexural strengths, or load
tests to be made on the portion of the building so affected. All such tests shall be made at
the Concessionaire’s expense.
e) Unacceptable concrete work shall be dismantled by the Concessionaire and replaced by fresh
work, meeting the specification requirements. In the course of dismantling, if any damage is
done to the embedded items or adjacent structures, the same shall be made good, by the
Concessionaire, to the satisfaction of the Project Engineer and Executing Agency, at no extra
cost to the Executing Agency.
f) Only as a very special case and that too in non-critical areas, the Project Engineer and
Executing Agency may accept concrete work which is marginally unacceptable as per the
criteria laid down in IS: 456.
g) Before placing concrete, the inside of forms shall be checked to ensure that they are clean
and thoroughly wetted or adequately treated. So as to prevent absorption of water from the
concrete.
h) Ultrasonic tests on the foundations of major equipment to ascertain the quality and grade of
concreting shall be carried out. The Executing Agency shall arrange for the specialized
agency for conducting the test at his cost. The Concessionaire shall provide all the necessary
facilities and arrangement for conducting the test at site in terms of access, scaffolding etc.
In case of any defects, the Concessionaire shall rectify the same as directed by the Project
i) Rebound hammer test shall be carried out for ascertaining the quality of concrete work, as
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j) Test shall be conducted for the water tightness of the liquid retaining structures as per IS:3370
and IS:6494. The details and sequence of tests shall be as given hereunder:
i) All arrangements, including supply of water for testing purposes, shall be kept ready
when the tank is nearing completion.
ii) Water supply to the tank shall be in stages of 300 to 450 mm height in order to check
the water tightness of the tank and location of leakage of various levels.
iii) The permissible drop in level in 24 hours shall be 6 mm in case of covered

reservoir/tank and 12 mm in the case of open reservoir/tank.
iv) The leakage points shall be marked and separately treated after dewatering.
v) The reservoir / tank shall be retested for water tightness after rectification.
vi) For basement type structures like cable vault, track-hopper, tunnel, neutralizing pit,
etc. the Concessionaire shall examine the water tightness against ingress of sub-soil
water.
 Sampling of concrete
Samples from fresh concrete shall be taken according to IS:1199 and tested as per IS:516.
a) Normally only compressive test shall be performed but the Project Engineer and Executing
Agency may require other tests to be performed in accordance with IS:516.
b) i) Trial Mixes:
Atleast four trial mixes shall be made with; min. 6 test cubes for each mix.
ii) Works Tests:
The min. frequency of sampling of concrete of each grade shall be according to clause
14.2.2 of IS:456-1978. However, after getting continuous satisfactory results and in the
case of voluminous concrete works, the Project Engineer and Executing Agency, may at
his discretion reduce the frequency of sampling as follows.
For each grade of concrete, and for each 8 hours (shift) of work or part thereof, atleast one
sample consisting of six specimens shall be taken from each 150 cum. of concrete or part
thereof, 3 specimens shall be tested at 7 days and remaining 3 shall be tested at 28 days.
However, in all cases, the 28 days compressive strength shall alone be the criterion for
acceptance or rejection.
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c) To control the consistency of concrete from every mixing, slump tests and compaction
factor tests in accordance with IS:1199 shall be carried out by the Concessionaire every
two hours or as directed by the Project Engineer and Executing Agency. Slumps
corresponding to the test specimens shall be recorded for reference.
d) The strength of sample shall be the average of the strength of three specimens. The
individual variation should not be more than 15% of the average.
 Unless otherwise specified, the tolerance in construction shall be as follows:
The dimensions of concrete as cast when compared with those on the drawings shall be within the
tolerance given below:
Description of item / structural element Permissible deviation in mm

Faces of concrete in foundations and structural members +25 -10
against which backfillis placed.
Location of footing (for RCC framed structures only). +25 -25
Eccentricity of footing 2% of footing width of direction of
misplacement but limiting to 50mm
Top surface of slabs and of concrete to receive base plates +5 -5
to be grouted.
Alignment of beams, lintels, columns, walls, slabs and +5 -5
similar structural elements
Deviation from specified dimensions of cross-sections of +12 -6
columns and beams
Alignment of holding down bolts without sleeves. +1.5 -1.5
Alignment of holding down bolts with sleeves. +5 -5
Level of holding down bolt assemblies. +10 -10
Embedded parts (in any direction). +5 -5
Centres of packets or holes with greatest lateral dimension +10 -10
not exceeding 150 mm. Variation in steps:
Riser +1.5 -1.5
Tread +3.0 -3.0
Plumb 3mm for every metre subject to a
maximum of 10mm.
 Acceptance criteria
The acceptance criteria of concrete shall be in accordance with Clause no.15 of IS:456. However,
in exceptional circumstances, the Project Engineer and Executing Agency may, at his discretion,
accept a concrete of lower strength than that specified at reduced rates. The concrete shall be
deemed to comply with the strength requirements if:
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a) Every sample has a test strength not less than the characteristic value or
b) The strength of one or more samples, though less than the characteristic value, in each case
is not less than the greater of :
i) The characteristic strength minus 1.35 times the Standard Deviation and
ii) 0.80 times the characteristic strength; average strength of all the samples, is not less
than the characteristic strength + [1.65 - 1.65/ square root of (No. of samples)] times
the standard deviation.
 Load test
If any work is found unacceptable whereupon the Project Engineer and Executing Agency requires
its removal and reconstruction, the Concessionaire may request that it should be load tested in
accordance with the provision of Clause no. 16.50 of IS:456-1978 as given below:
a) The test load shall be 125 percent of the maximum superimposed load for which the structure
or element was designed. This load shall not be applied earlier than 28 days after the effective
hardening of concrete. This test load shall be maintained for 24 hours and during the entire
duration of the test, struts, strong enough to take the whole superimposed, dead and other
loads shall be placed in position, leaving a small gap under the members.
b) The maximum deflection shall be measured after the test load is in position for 24 hours.
Thereafter, the test load shall be removed.
c) If 24 hours after the removal of the load, the structure does not show a recovery of atleast 75
percent of the maximum deflection, registered as in (b) above, the test shall be repeated after
a lapse of 72 hours. The structure shall be considered to have failed to pass the test if the
recovery after the second test is not atleast 80% of the maximum deflection during the second
test.
d) If the maximum deflection in mm, shown during 24 hours under load, is less than 40 l sq /
D, where I is the effective span in metres and D is overall depth of the section in mm, it is
not necessary for the recovery to be measured and the recovery position of the above
mentioned clause (c) will not apply.
Reinforcement
3.1.11 Scope
This section of the specification deals with reinforcement for all reinforced concrete works and
covers the requirement of materials, their properties, storage, handling, furnishing of bar bending
schedules and the cleaning, bending, binding and placing of reinforcement with suitable cover
blocks. This shall also include the supply of reinforcement, wherever required.
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3.1.12 General requirements
The Concessionaire shall prepare and furnish to the Project Engineer and Executing Agency, bar
bending schedules for all RCC works for his review and approval. No work shall commence
without the approval of bar bending schedule by the Project Engineer and Executing Agency, in
writing.
The Concessionaire shall have to obtain prior written approval from the Project Engineer and
Executing Agency, if he desires any adjustments in diameter or spacing of reinforcement. However,
the Concessionaire shall modify the bar bending schedule, when a particular type and size of
reinforcement would not be available, with the approval of the Project Engineer and Executing
Agency.
3.1.13 Materials
All steel for reinforced concrete works shall be in accordance with Technical Specification for
Properties, Storage and Handling of common Building Materials, (vide module C2) which shall be
deemed to form the part of this Specification.
All bars shall be thoroughly cleaned before being fabricated. Pitted and defective bars shall not be
used.
3.1.14 Bending and placing
 Bending
a) Reinforcing bars supplied bent or in coils, shall be straightened before these are cut to size.
Straightening of bars shall be done in cold and without damaging the bars. This is to be
considered as a part of reinforcement bending and fabrication work.
b) Unless otherwise specified, reinforcing steel shall be bent in accordance with procedure
specified in IS:2502 and/or as approved by the Project Engineer and Executing Agency.
Bends and shapes shall comply strictly with the dimensions shown on the approved bar
bending schedules and they shall be rechecked by the Concessionaire before bending and he
shall be entirely responsible for their correctness. Bars correctly bent, shall only be used.
Unless specified otherwise or directed by the Project Engineer and Executing Agency, the
detailing of reinforcement shall be in accordance with IS: 5525 and SP: 34.
c) No reinforcement shall be bent, when in position in the work without approval of the Project
Engineer and Executing Agency, whether or not it is partially embedded in concrete. Where
the reinforcement bars are bent aside, at construction taken to ensure that, at no time, the
radius of the bend is less than 4 times the bar diameters for plain mild steel or 6 times the bar
diameters for deformed bars. Care shall also be taken while bending back bars, to ensure that
the concrete around the bar is not damaged.
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d) Welding of bars to obtain continually shall not be allowed, particularly for cold twisted bars,
unless specifically approved by the Project Engineer and Executing Agency. If welding is
approved, the work shall be carried out as per IS: 2751 and IS: 9417, according to the best
practice and as directed by the Project Engineer and Executing Agency.
 Placing in position
a) All reinforcement shall be accurately fixed and maintained in position as shown on the
drawings by such approved means as steel chairs, and/or concrete spacer blocks as per
IS:2502. Bars intended to be in contact at crossing points by two numbers annealed steel wire
of 0.9 mm to 1.6 mm size conforming to IS:280 in such a manner that they do not slip over
each at the time of fixing & concreting. The tying of bars shall be in crisscross manner.
b) Binders shall tightly embrace the bars with which these are intended to be in contact and shall
be securely held. The vertical distance between successive layers of bars shall be maintained
by provision of spacer bars. These shall be so spaced that the main bars do not sag
perceptively between adjacent spacers.
Bundled bars shall be provided wherever shown on the drawing to facilitate concreting.
Location of laps and development lengths, shall be as indicated on the drawings.
c) The placing of reinforcement shall be completed well in advance of concrete pouring. Just
prior to concrete pouring, the reinforcement shall be checked by the Project Engineer and
Executing Agency, for accuracy of placement and cleanliness. Necessary corrections, as
directed by the Project Engineer and Executing Agency shall be carried out. Care shall be
taken to ensure that projecting ends of ties and other embedded metal do not encroach into
the concrete cover. Where concrete blocks are used for ensuring the cover and positioning of
reinforcement, these shall be made of mortar 1:2 (1 cement: 2 sand) by volume and cured for
at least seven days. The sizes and locations of the concrete blocks shall be approved by the
Project Engineer and Executing Agency. The 28 days crushing strength of cover blocks shall
be atleast equal to the specified strength of concrete in which the blocks will be embedded.
d) Laps and anchorage length of reinforcing bars shall be in accordance with IS:456, unless
otherwise specified. If the bars in a lap are not of the same diameter, the smaller diameter
will guide the lap length. Laps shall be staggered as far as practicable and as directed by the
Project Engineer and Executing Agency and not more than 50% of bars shall be lapped at a
particular section. Mechanical connections, for splicing reinforcement bars in congested
locations may be used by the Concessionaire, only if approved by the Project Engineer and
Executing Agency. Reinforcement bars shall not be lapped unless the length required
exceeds the maximum available lengths of bars at site.
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3.1.15 Cover to reinforcement
a) Unless shown otherwise on the drawings, minimum clear concrete cover for reinforcement
(exclusive of plaster or other finishes) shall be as follows:
 At each end of a reinforcing bar, not less than 25 mm, nor less than twice the bar
diameter.
 For a longitudinal reinforcing bar in a column, 40 mm or bar diameter whichever is
more. 25 mm cover may be adopted for columns of minimum dimension 200 mm or
under and with longitudinal reinforcement diameter not exceeding 12 mm.
 For longitudinal reinforcing bars in a beam, not less than 25 mm or less than the bar
diameter.
 For reinforcement in slabs and walls; not exposed to weather or ground not less than
15 mm nor less than the bar diameter.
 For bottom reinforcement in footings: 75 mm, if concrete is laid against the ground or
40 mm if laid on a layer of lean concrete.
 For retaining walls, grade beams, top and sides of footings and similar surfaces
exposed to weather or ground; 50 mm for bars larger than 16 mm and 40 mm for bars
upto 16 mm.
 For concrete members exposed to the action of harmful chemicals, acids, alkalis,
atmosphere, sulphurous smoke, seawater etc., the cover shall be as shown on the
drawings.
 For liquid retaining structures; 40 mm or diameter of main bars, whichever is larger.
This shall be increased to 50 mm in case of seawater or corrosive environment.
b) Clean distance between reinforcing bars shall be in accordance with IS:456 or as shown on
drawings.
3.1.16 Sampling, testing and quality assurance
 General
Sample bent bars shall be checked to ensure that they conform to the bar bending schedules.
Reinforcement in position shall be checked for proper positioning, and rigidity, cover, spacing of
bars, placement of chairs and spacers, etc. Also it shall be checked that all bars at crossings are
properly tied.
 Tolerance
Tolerance in construction, unless otherwise specified or as approved by the Project Engineer and
Executing Agency shall be as follows:
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Description of item / structural element Permissible deviation in mm (Max.)
Placing of reinforcement
For effective depth 200 mm or less +10 -5
For effective depth more than 200 mm +15 -10
Cover to reinforcement -5
Cutting of reinforcement
When minimum length specified +75 -
When maximum length specified - -50
When maximum or minimum length not +75 -25
specified
Formwork and staging
3.1.17 Scope
This section of the specification deals with the requirements for the supply, erection, dismantling
of formwork and staging required for cast-in-situ concrete works including for making pockets /
block outs.
3.1.18 General conditions
The Concessionaire shall supply, fabricate, erect, and dismantle (after use) all staging that is
required for all activities covered under the specifications. He shall prepare the scheme and submit
along with the supporting calculations for approval of the Project Engineer and Executing Agency.
3.1.19 Materials
Formwork shall compose of steel, best quality wood or non-absorbent type plywood. Timber shall
be free from significant knots and shall be of medium grain as far as possible and hard woods shall
be used as caps and wedges under or over posts. Timber shall be well seasoned, free from sap,
shakes, worm holes, warps or other surface defects and shall have smooth finish.
Staging, unless specified otherwise, shall generally be of mild steel tubes, steel beams and channels
etc. or strong sal ballies 150 mm in diameter or above. Bamboos, small diameter ballies etc., shall
not be used unless approved by the Project Engineer and Executing Agency in specific cases.
3.1.20 Classification of formwork
a) Ordinary
This shall be used in places where ordinary surface finish is required and shall compose of
steel and/or approved good quality seasoned wood. Plywood shuttering can also be used by
the Concessionaire.
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b) Plywood
This shall be used in exposed surfaces as shown on drawings or as directed by the Project
Engineer and Executing Agency where a specially good finish is required. Such surfaces
shall be formed using approved brand of heavy quality water resistant plywood to produce a
perfectly leveled, uniform and smooth surface. Reuse of such forms may be permitted only
after inspection and approval by the Project Engineer and Executing Agency, for each such
reuse.
c) Formwork for shell roofs
For this item, the detailed design of formwork shall be submitted by the Concessionaire to
the Project Engineer and Executing Agency, well in advance, for his approval. Units of shell
forms may be used repeatedly but prior approval shall be required for each repetition. Extra
care shall be taken to keep correct levels and profiles.
3.1.21 Quality of formwork and staging
Formwork shall consist of all materials required for forming the boxing to pour concrete, including
steel / wood / plywood forms, ties, anchors, hangers, inserts, etc. Formwork shall be so constructed
that vertical and horizontal adjustments can be made as required. The design and engineering of
formwork including staging as well as its erection and dismantling shall be the responsibility of the
Concessionaire.
The staging shall be true and rigid and thoroughly braced in both directions as well as cross braced,
strutted and propped such that it will not deform unduly under weight of concrete and other loads
due to men, equipment, etc. Vertical member or props should not be supported on an unpropped
lower suspended floor or beam unless it is ensured by the Concessionaire that the lower floor or
beam can safely carry the loads. No propping shall take place until the Project Engineer and
Executing Agency’s approval has been given to the Concessionaire’s scheme submitted along with
supporting calculations.
The forms and staging shall be sufficiently strong to carry without under deformation, the dead
weight of the concrete as liquid as well as anticipated working loads. Where the concrete is vibrated,
the formwork shall be strong enough to withstand the effects of vibration, without appreciable
deflection, bulging, distortion or loosening of its components. The joints in the formwork shall be
sufficiently tight to prevent any leakage of mortar. The formwork shall be such as to ensure a
smooth uniform surface free from honeycombs, air bubbles, bulges, fins and other blemishes. Any
blemish or defect found on the surface of the concrete, must be brought to the notice of the Project
Engineer and Executing Agency immediately and rectified as directed.
To achieve the desired rigidity, ample studs, braces, bolts, spacer blocks, wires, clamps, ties, straps,
shores, etc. Shall be used to hold the form in proper position without undue distortion. These shall
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be approved by the Project Engineer and Executing Agency but they must in no way impair the
strength of concrete or leave stains or marks on the finished surface. Where there are chances of
these fixtures being embedded, only mild steel or concrete of adequate strength shall be used. Bolts
passing completely through liquid and or earth retaining walls / slabs, basement walls etc. For the
purpose of securing and aligning the formwork, shall not be permitted.
For exposed interior and exterior concrete surfaces of beams and columns, plywood or other
approved forms thoroughly cleaned and tied together with approved corrosion resistant devices
shall be used. Rigid care shall be exercised ensuring that all column forms are plumb and true and
thoroughly cross-braced to keep them so.
Beveled strips 25x25 mm shall be provided to form angles and in corners of columns and beam
boxes for chamfering of corners if shown on drawings or directed by the Project Engineer and
Executing Agency. Temporary openings for cleaning, inspection and for pouring concrete shall
be provided at the base of vertical forms and at other places, where these are necessary and as may
be directed by the Project Engineer and Executing Agency. The temporary openings shall be so
formed that they can be conveniently closed rigidly when required and must not leave any mark on
the concrete.
If it is so desired by the Project Engineer and Executing Agency, the Concessionaire shall prepare,
before commencement of the actual work, designs and drawings for formwork and staging and get
them approved by the Project Engineer and Executing Agency. Formwork shall be so designed and
positioned that it can be removed without damage to concrete.
The Concessionaire shall maintain necessary camber in centering for all floor slabs and beams in
all spanning directions, so as to offset the deflection and assume correct shape. The camber shall
have the crown of not less than 8 mm for every 5 metres span unless otherwise shown on the
drawings. For cantilever, camber at free end shall be 1 in 100.
The Concessionaire shall provide the shuttering for complete stretch of work upto expansion joints
for the structures like shell, folded plate etc. and/or as directed by the Project Engineer and
Executing Agency.
3.1.22 Cleaning and treatment of forms
All forms shall be thoroughly cleaned of old concrete, wood shavings, saw dust, dirt and dust
sticking to them before these are fixed in position. All rubbish, loose concrete, chippings, shavings,
saw dust etc. shall be scrupulously removed from the interior of the forms before concrete is poured.
Wire brushes, brooms, compressed air jet and/or water jet etc. shall be kept handy for cleaning, if
Before formwork is placed in position, the form surfaces that will be in contact with concrete shall
be treated with approved non-staining oil or composition, which is insoluble in water and not
injurious to concrete. Care shall be taken that the oil or composition does not come in contact with
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reinforcing steel or stain the concrete surfaces. Burnt oil shall not be allowed to be used specially
where the concrete surface will require finishing and/or plaster.
3.1.23 Removal of forms
The Concessionaire shall begin the removal of formwork only after the approval of the Project
Engineer and Executing Agency. He shall place on record the dates on which the concrete is placed
in different parts of the work and the dates of the removal of formwork therefrom. This record shall
be checked and countersigned by the Project Engineer and Executing Agency. The Concessionaire
shall be responsible for the safe removal of formwork but the Project Engineer and Executing
Agency may delay the time of removal if he considers it necessary. Any work showing signs of
damage through premature removal of formwork, shall be entirely removed and reconstructed by
the Concessionaire at no extra cost to the Executing Agency.
The formwork shall be so designed and erected that the forms for slabs and the sides of beams,
columns and walls may be removed first, leaving the beam bottoms and their supports in position.
Re-propping of beams shall not be done except with the approval of the Project Engineer and
Executing Agency. Formwork for columns and walls at each stage of concreting shall be erected
only upto the particular lift of construction. Wedges, spacer bolts, clamps or other suitable means
shall be provided to allow accurate adjustment of the formwork and to allow it to be removed
gradually without jerking the concrete.
Forms of various types of structural components shall, under normal circumstances, not be removed
before the minimum periods specified in Cl. 10.3 of IS:456-1978, which shall also be subject to the
approval of the Project Engineer and Executing Agency. However, in any case formwork shall not
be struck until the concrete has reached strength, atleast twice that of the stress to which the concrete
may be subjected to at the time of removal of forms.
In normal circumstances and where ordinary Portland cement is used, forms may generally be
removed after the expiry of the following periods, according to clause no. 10.3 of IS:456-1978.
i. Walls, columns and vertical faces of all structural members 1 to 2 days

as directed by the Project Engineer and Executing Agency.
ii. Slabs (Props left under) 3 days
iii. Beam soffits (props left under) 7 days
iv. Removal of props under slabs
Spanning up to 4.5 m
Spanning up to 4.5 m 14 days
v. Removal of props under beams
Spanning up to 6 m 14 days
Spanning over 6 m 21 days
vi. Cantilever slabs 14 days
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The number of props left under, their sizes and disposition shall be such as to be able to safely carry
the full dead load of the slab, beam or arch as the case may be together with any live load likely to
occur during curing or further construction.
Where the shape of the element is such that the formwork has reentrant angles, the formwork shall
be removed as soon as possible after the concrete has set, to avoid shrinkage cracking occurring
due to the restraint imposed.
In case of cantilever slabs, the removal of forms shall begin from the outer edge and proceed
towards the support, where as in the case of slabs supported on two/four sides, the removal of forms
shall begin from centre to supports.
The formwork shall be so made as to produce a finished concrete, true to shape, lines, plumb and
to dimensions as shown on the drawings. The Project Engineer and Executing Agency may call for
finished work at any time to set standards of workmanship. Once approved, these will become the
accepted Sample.
In case PPC/PSC is used instead of OPC, the removal of shuttering/support shall be after 50% more
time from that being applied for OPC, unless otherwise permitted by the Project Engineer and
Executing Agency. For concrete temperature above 40 C, stripping time shall be increased.
In case of special structures, such as shells, folded plates, etc., the sequence of removal of forms
shall be as per drawings or as directed by the Project Engineer and Executing Agency.
3.1.24 Reuse of forms
Before reuse, all forms shall be thoroughly scraped, cleaned, all nails and adhering substances
removed, holes and leaks satisfactorily plugged, joints examined and where necessary repaired and
inside surfaces treated as specified herein before. Formwork shall not be used/re-used, if declared
unfit or unserviceable by the Project Engineer and Executing Agency.
3.1.25 Testing and quality assurance (including dimension tolerance)
 General
Staging shall be checked for its soundness as a whole and for adequacy of the joints and its
foundations. All joints shall be either vertical or horizontal and shall be such as to avoid loss of
liquid through the formwork.
 Dimensional tolerance for formwork
Levels and heights  6 mm

Plumb 3 mm for every meter subject to a maximum of 10mm.
Unevenness of any surfaces  3 mm
Length or breadth  12 mm
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Diagonals  15 mm
In case of inclined surfaces like track hopper wall, folded plates etc., the deviation in the alignment
of inclined surfaces, shall not exceed 3 mm with reference to the theoretical alignment, for a length
of 1000 mm measured vertically, subject to a maximum of 10 mm.
In addition to above, requirement of clause no. 10.3 shall be complied with, which shall be the final
acceptance criteria of concrete work.
Embedded parts
3.1.26 Scope
This section of specification deals with the supply, fabrication (where called for) and/or erection of
embedded steel parts and PVC pipes
Embedded steel parts shall be furnished by the Executing Agency for transportation & erection by
the Concessionaire or supplied, fabricated and erected by the Concessionaire as stipulated. If
supplied by the Executing Agency, these parts shall be furnished anywhere within the project area
and the Concessionaire shall transport the same to the work site.
a) Embedded steel parts supplied, fabricated and erected by the Concessionaire shall include
items such as, but not limited to, foundation grillages, anchor bolts, pipe sleeves, equipment
mounting plates, steel pieces properly welded with necessary lugs as shown on the drawings,
auxiliary framing for equipment supports, pesty plugs for door and window frames, dowel
bars for concrete work, miscellaneous frames, etc.
b) Embedded steel parts supplied, fabricated/erected by the Concessionaire shall also include
items such as, but not limited to plate inserts, edge protection angles, rolled sections with or
without properly welded lugs.
c) Cold work deformed steel bars shall not be used for lugs.
3.1.28 Materials
The materials shall be in accordance with the relevant clauses of Technical Specification for
‘Properties, Storage and Handling of Common Building Materials (vide module C2), which shall
be deemed to form a part of this specification. Mild steel pipes shall conform to IS:1161. Unless
otherwise specified, medium class pipes shall be provided/ PVC pipes shall conform to IS:4985.
Minimum pressure rating shall be 2 Kgf/cm2.
3.1.29 Fabrication, erection etc.
184
The Concessionaire shall fabricate, transport to site and erect accurately in position all embedded
steel parts either by welding, bolting or any other means as approved by the Project Engineer and
Executing Agency. Exposed surfaces of embedded parts other than holding down bolts, unless
otherwise stated, are to be painted with two coats of approved anticorrosive paint (as per IS:2074)
and/or bituminous paint as directed. The threads of holding down bolts shall be greased and
protected with waterproof tape.
During erection, the Concessionaire shall provide necessary strong temporary bracings and
supports to ensure proper installation of the embedded parts which shall be erected at the true
locations as shown on the drawings and these shall be in plumb and level (unless otherwise shown
on drawings). The Concessionaire shall furnish the Project Engineer and Executing Agency with
fabrication and assembly drawings prepared for embedded steel parts showing the erection
procedure, for major items, wherever necessary.
Fabrication & erection shall be carried out as per IS: 800. Welding rods & site / field welding shall
conform to IS: 816 and IS: 9595. IS: 7634 (Part - III) shall be followed for PVC pipe works.
Foundation bolt assembly
3.1.30 Scope
This section of the specification deals with the requirements of supply, fabrication and erection of
foundation bolt assembly etc.
Supply, fabrication, erection and installation of Foundation bolt assembly shall comprise of
foundations bolts, stiffener plates, washers, nuts, lock nuts, pipe sleeves etc.
3.1.32 Materials
Foundation bolts shall generally conform to IS:5624. Mild steel bars used for the fabrication of bolt
assembly shall conform to grade-I of IS:432, IS:226, IS:2062 or any other material including high
carbon/high tensile steel as specified.
Hexagonal nuts and lock nuts shall conform to IS:1363 & IS:1364 upto M 36 dia and IS:3138 and
M 42 to M 150 dia.
Flat plain washers shall be of mild steel and punched/machined type conforming to IS:5369.
Steel pipe sleeves shall conform, to Medium class of IS:1161.
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3.1.33 Fabrication, erection, etc
The fabrication and erection of bolt assemblies shall include threading, cutting, grinding, drilling,
welding, etc., complete. All bolts, bolts assemblies, etc. shall be fabricated by the Concessionaire
to the correct dimensions and shapes as shown on drawings, supplied by the Engineer. The bolts
shall have coarse pitch screw thread in the diameter range, 8 to 64 and 6 mm pitch screw for
diameter  64 mm as per IS: 4218.
For fabrication of any particular size of bolt indicated on the drawing, the diameter of the threaded
portion of the bolt shall be considered as the diameter of the bolt.
Every bolt shall be provided with steel washer, under the nut. The washer shall be flat and min.
outside circle have a diameter 2.50 times that of the bolt and of suitable thickness. All nuts shall be
of steel with well formed hexagonal heads unless specified otherwise, forged from solid metal and
shall be dipped in hot boiled linseed oil as soon as these are made. The nuts shall fit good on the
bolts.
During erection, the Concessionaire shall provide necessary template, temporary bracings,
supports, etc. to ensure proper positioning of the assemblies and holding them firmly until they are
cast / grouted and the grouted has set. All materials shall be erected in plump and in level (unless
otherwise specified) and at true locations as shown on the drawings. Threads shall be protected by
using PVC taps.
Fabrication & erection shall be carried out as per IS:800. Welding shall conform to IS:816 and
9595.
Shotcreting
3.1.34 Scope
This section of the specification deals with the requirements of furnishing and placement of
shotcreting.
Generally, shotcreting shall be done in accordance with IS:9012.
Reinforcement for shotcreting shall be as detailed below, unless specified otherwise.
a) Reinforcement in one direction consisting of 6 mm M.S. bars at 750 mm c/c shall be

connected to the lugs of fastening of the wire fabric. This shall be used in case of 50 mm or
above thick shotcreting.
b) Wire fabric conforming to IS:1566 shall be used as reinforcement and shall consist of wire,
3 mm diameter, spaced 50 mm both ways and shall be electrically cross welded. Wire fabric
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shall be securely tied to 6 mm bars for 50 mm (min) thickness. Adjacent sheet of wire fabric
shall be lapped at least 100 mm tied.
c) Clear cover to reinforcement mesh shall not be less than 15 mm.
This work shall be executed only by experienced operators, approved by the Project Engineer and
Executing Agency.
Minimum thickness shotcreting shall be 50 mm. for abrasion resistant and 25 mm for ordinary
surface protection work.
3.1.36 Materials
Generally, the materials shall be in accordance with the relevant clauses of Technical Specification
for properties. Storage and Handling of common Building Material, which shall be deemed to form
a part of this Specification.
a) Fine aggregates shall consist of natural sand or crushed stone from a known source and shall
be strong, hard, coarse, sharp chemically inert, clean and free from any coating. It shall be
free from clay, coal or coal residue, organic or any other impurities that may impair the
strength or durability of the concrete and shall conform to IS: 383.
b) Fine aggregate (sand) shall be well graded and particles shall range in size within the
following limits. The Project Engineer and Executing Agency, may approve the use of any
other grading as per the requirements of IS: 9012.
IS sieve designation Percentage passing by weight

10 mm 100
4.75 mm 90 – 100
2.36 mm 60 – 95
1.18 mm 45 – 80
600 microns 35 – 60
300 microns 8 – 30
150 microns 0 – 10
c) The fineness modules shall be preferably between 2.5 & 3.3. Any other value can be used,
with prior approval of the Project Engineer and Executing Agency.
Water shall be clean & free deleterious matter and shall have same properties, stipulated for use in
concrete work.
Set accelerating and water-proofing shotcreting admixtures of approved make shall be used
wherever required.
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3.1.37 Application
After the placement of reinforcement and/or welded mesh and not more than six hours prior to the
application of shotcrete, the surface shall be thoroughly cleaned of all loose material and dirt. The
Concessionaire shall properly prepare the surfaces, reinforcement and/or welded mesh to receive
the shotcrete. Cleaned surfaces shall be wetted not more than one hour prior to shotcreting.
The mix as placed on surface shall one part cement to three parts approved sand by volume. Cement
and sand shall be dry mixed; no water shall be added after mixing and before using in the gun. The
quantity of water when added, shall be only that which is sufficient to hydrate the cement. For
average atmospheric conditions, the water cement ratio for shotcrete in place shall be between 0.35
and 0.5. Suitable admixture shall be used wherever required.
A uniform pressure of not less than 2.5 Kgf/cm2 at the nozzle shall be maintained. Necessary
adjustments shall be made to ensure this pressure, taking into account the length of hose and height
of the place to be shotcreted.
The application shall proceed in an upward direction. Beams, stiffener and intermediate walls, if
any, shall be wrapped with wire fabric and completely covered with shotcreting. All rebound shall
be removed from the area of application as the work progresses and such rebound material shall
not be reused.
3.1.38 Curing
As soon as the freshly shotcreted surface shows the first dry patches, a fine spray of water shall be
applied to keep it moist. After the surface has hardened, it shall be kept continuously moist for
minimum seven days. If there is extreme heat, especially when accompanied by hot winds, the
shotcreted surface, immediately upon completion, shall be covered with burlap of similar covering,
which must be kept continuously moist for 14 days after shotcreting. The temperature of the lining
shall not be permitted to exceed 38 Degrees Centigrade during placing and curing.
Grouting
3.1.39 Scope
This section of the specification deals with the requirements of furnishing and placement of grout
in block outs and foundation bolt holes and underpinning of base plates In case special type of
grouting is required for the machine base plate, the Concessionaire shall submit the details of the
same and get it approved from the Project Engineer and Executing Agency.
The space between the top surface of the foundation and the underside of the base plate shall be
filled with appropriate grout.
188
Crushing strength of grout shall be one grade higher than the foundation concrete. Minimum
crushing strength shall be 25N/sq.mm. Unless otherwise specified.
The contact area between the grout and base plate shall not be less than 80%.
3.1.41 Materials
Cement shall be Ordinary Portland Cement slag cement or Pozzolana Portland Cement conforming
to IS:269, 455 and 1489 respectively.
Sand shall be clean and well graded conforming to IS 383. For flow able grout, sand conforming
to Zone - 4 grade shall be used. Coarse aggregate wherever used shall also conform to IS:383.
Clean potable water as recommended for concrete mix shall be used.
 Admixtures
a) Non-shrink admixtures of approved make shall be used.

b) Plasticizer conforming to IS:9103 shall be used to increase the workability, wherever
required.
3.1.42 Mixing and placing
 Type of mix
There shall generally be following three types grout mix::
i) Ready mixed non-shrink cementations grout

ii) Cement-Sand Grout: The proportion of cement to sand shall generally be 1:2, unless
otherwise specified.
iii) Cement Aggregate Grout: The approximate proportions of cement, sand and coarse
aggregate shall be 1:1:25:2, with a maximum size of aggregate as 10 mm. This mix shall
generally be used for grout thickness above 40 mm for dry pack application.
 Mixing
Depending upon the case of placement and method of application, there shall be following three
grout consistencies.
a) Fluid Mix: Water cement ratio shall be 0.6 (max.) may be added to increase workability,
wherever required. This grout mix shall be suitable for application with low pressure grouting
equipment or self flowing and suitable for grouting of pockets/block outs, etc.
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b) Plastic Mix: Water-Cement ratio shall be about 0.5. This grout mix shall be suitable for
application with trowel or rod.
c) Stiff Mix: Water-cement ratio shall generally be 0.4. This grout mix shall be suitable for
dry-pack application. The consistency should allow pressurizing into firm hardball without
cracking.
 Placing
The block outs, bolts holes etc. Which have to be grouted, shall be cleaned thoroughly by use of
compressed air just prior to taking up the grouting operations.
Cement, sand, aggregate, and non-shrink admixture of approved quality and proven make shall be
first blended thoroughly in the required proportion as per manufacturer’s specifications. Grout shall
then be prepared by mixing this admixture with water. Any grout which has been mixed for a period
longer than half an hour shall not be used on the work.
Immediately after preparation, a grout of suitable mix shall be poured into the block outs, pockets
and bolt holes either from the sides or through the holes provided for this purpose in the base plate,
by using special equipment for pressure grouting. It shall be ensured by Roding and by tapping of
bolts that the block out is completely filled without leaving any voids. The pouring shall cease as
soon as each hole is filled and any excess grout found on the surface of the concrete foundation
shall be completely removed and the surface dried.
The space between the top surface of the foundation concrete and the underside of the base plate
shall be filled with appropriate grout type. Grouting, once commenced, shall be done continuously.
Grout shall be worked from one end to the other (to prevent air entrapment) and until the grout
oozes out through the grout holes provided in the base plates.
In case of stiff mix, the space between the top surface of foundation concrete and the underside of
the base plate shall be dry packed by firmly pressing or ramming into place against fixed supports.
When it is clear that the centre of base has been properly filled, the grout outside the base plate
shall be briefly rammed to ensure compaction below the edges. Shims provided for the alignment
of plant bases shall be positioned at the edges of the base to permit subsequent removal, which shall
take place not less than 7 days after the grouting has been executed. The resulting cavities shall be
made good with the same grade of grout as has been used for grouting under the rest of the base
plate.
 Curing
The work shall be cured for a period of atleast 7 days commencing 24 hours after the completion
of the grouting. The curing shall be done by covering the surfaces with wet gunny bags and
flooding.
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Encasement of steel structures / elements
3.1.43 Scope
This section of specification deals with the requirement for encasement of steel work in concrete
with necessary formwork, placing, finishing and curing, complete as per drawings and
specifications.
All concrete work, reinforcement, formwork & staging work shall be done as per stipulations of
section 2, 3 and 4 of this specification.
The reinforcement to be provided for encasement of steel elements shall be mild steel bars or in the
form of wire netting. Such reinforcement shall be kept 20 mm away from the steel member and
held securely to it.
The minimum grade of concrete to be used for encasing shall be M-20 unless specified. The
aggregate to be used in concrete shall be 12.5 mm maximum size unless specified otherwise. In
case of box type steel sections, encasement shall be done with cement, sand mortar (1:4) with
thickness of 50mm over 0.9 mm size wire netting conforming to IS:3150, or as shown on the
drawings.
In the case of encasement of beams with concrete, if the gap between the edge of the shuttering and
flange is hardly sufficient for placing the concrete, the workability of the concrete shall be increased
suitably by increasing the water-cement ratio.
Minimum cover for concrete encasement shall be 50 mm
3.1.45 Materials
The materials shall be in accordance with the relevant clauses of Technical Specification for
Properties, Storage and handling of common Building Materials which shall be deemed to form the
part of this specification.
3.1.46 Wire netting
Hexagonal wire netting shall be 0.9 mm dia and 19 mm aperture size, conforming to IS:3150.
Joints in concrete
191
3.1.47 Scope
This section of the specification deals with the requirement of furnishing and installing of joints
including joint filler materials, water bars, resilient pads type vibration damping material in an
around the side of concrete works etc.
Details of joints shall be as approved by Project Engineer and Executing Agency or as per approved
drawings. Where necessary or / and specified, joints shall be made water tight by use of water stops.
3.1.49 Classification of joints
From the point of view of utility, the joints as provided may be classified as below:
a) Construction joints
Construction joints are produced by placing fresh concrete against surface of hardened
concrete. Construction joints are generally, but not necessarily, vertical or horizontal.
Requirements of construction joints shall be as per clause specified elsewhere.
b) Contraction joints
These are provided to eliminate tensile stresses due to shrinkage and are commonly used
where temperature variations are small and where there is no likelihood of expansion, such
as spaces below water and earth levels and unexposed to atmosphere. At contraction joints,
the reinforcement is discontinued and bond is not allowed to develop between the joint faces,
thereby introducing a structural discontinuity. A contraction joint also serves as a
construction joint so far as break in the pouring of concrete is concerned.
c) Expansion joints
These are provided either to completely eliminate or to significantly reduce comprehensive

stresses in concrete that would otherwise result from thermal expansion and might crush,
buckle or crack part of the structure. Expansion joints serve the purpose of contraction and
also construction joints.
d) Control joints
At places where cracking is inevitable, places of weakness are introduced by the provision
of control joints so that the cracking takes place along these joints instead of allowing it to
develop in a haphazard manner.
e) Separation joints
192
The places where the expansion of the structure is not expected but they are required to be
kept structurally separate so that stresses, vibrations, etc. are not transferred, a separation
joint should be provided. Like expansion joint, a gap is provided in separation joint also, but
this is not expected to be used by the expansion of members. In case, no gap is required, the
separation joint can be obtained by using an approved alkathene sheet stuck on the surface
against which concrete shall be placed.
f) Settlement joints
Structures, which are likely to settle with respect to the adjacent structures, shall be separated
by a settlement joint so that the adverse effects of differential settlement are obviated. It is
like an expansion joint but with a different sealing arrangement.
3.1.50 Materials
 Joint filler
a) Bitumen board:
The bitumen impregnated fiber board; a preformed material shall be used as joint filler
which shall fill space between the concrete surfaces at the joints. The minimum thickness
of board shall be 12 mm and the material shall conform to IS:1838.
b) Expanded polystyrene :
The expanded polystyrene slab shall be of fire retarding grade (type-2) conforming to
IS:4671 Density of material shall not be less than 25 kg/cum.
 Water stops
a) Water stops shall be provided at the joints as a continuous diaphragm to contain the filler
material and/or to exclude passage of water or any other material into or out of the structure.
b) The water stops shall be either metallic like Copper, or non-metallic like P.V.C. the material
is to be procured from reputed manufacturers having proven records of satisfactory supply
of Water Stops of similar make and shape of other jobs. Only PVC water stop shall be used,
unless, otherwise, specifically approved by the Project Engineer and Executing Agency.
c) Non-metallic Water Stop :
These will be normally in PVC and can be of shape having any combination of the following
features:
i) Plain
ii) Central Bulb
iii) Dumb-bell or flattened ends
193
iv) Ribbed and Corrugated Wings
v) V-shaped
vi) Kicker type (Externally placed)
Water bars shall generally meet the stipulations of IS: 12200. The minimum thickness of
PVC Water Stops shall be 5 mm and the minimum width 225 mm, unless otherwise specified
in the schedule of items. However, for some non-critical areas 150 mm wide and 5 mm thick
water stop can be used. The actual size and the shape will be as shown on drawings and/or
as directed by the Project Engineer and Executing Agency. The material should be of good
quality Polyvinyl Chloride, highly resistant to tearing, abrasion and corrosion as well as to
chemicals likely to come in contact with during use. The performance requirements shall
generally be as follows:
Sp. Gr : 1.3 to 1.4

Shore hardness : 60A to 80A
Tensile strength : 116kgf / cm2 min.
Max. Safe continuous temp. : 70 degree C.
Ultimate elongation : Not less than 300%
Tear resistance : 45kgf / cm2 min.
Stiffness in flexure : 25kgf / cm2 min.
Accelerated extraction
i) Tensile strength : 110kgf / cm2
ii) Ultimate elongation : 250%
iii) Water absorption in 7 days : 5% (max.)
Effect of Alkali : 7 days

1. Weight increase : 0.25% max.
2. Weight decrease : 0.10% max.
3. Hardness change : +5%
Effect of Alkali : 28 days

a) Weight increase : 0.40% max.
b) Weight decrease : 0.30% max.
c) Dimension change : +1%
 Sealing compound
a) Bitumen sealing compound:

The bitumen sealing compound shall be from approved manufacturer and shall conform to
the requirements of IS:1834. For joints in concrete lining on canals/reservoirs, sealing
compound conforming to IS:5256 shall be used.
194
b) Polysulphide sealing compound:
This shall be two-part polysulphide sealant and shall be from approved manufacturer,
conforming to IS:12118. Materials shall consist of polysulphide polymer and a curing agent.
Gun grade material shall be used unless otherwise specified. The application of the sealant
shall be strictly followed as per manufacturer’s guidelines.
 Metal cover strips
Metal cover strips shall be made from aluminium or mild steel sections as shown on drawings. The
min. thickness of aluminium strips shall be 3 mm and that of mild steel 6 mm. Aluminium alloy
strip shall be corrosion resistant grade 31000 as per IS:737. Mild Steel shall conform to IS:226 or
IS:2062.
 Resilient pads
i) The vibration damping material shall be resilient rubber pads made up of natural or synthetic
rubber and shall have the following physical properties
a) Shore ‘A’ durometer hardness : 50 (+) / (-) 5

b) Min. elongation : 450%
c) Ultimate min. tensile strength : 145 kg/sq.cm
d) Rubber pads shall not absorb more than 10% of weight of water in a 7 days test.
ii) The minimum thickness of the resilient pads shall be 12 mm.
3.1.51 Installation
 Bitumen board / Expand polystyrene
The bitumen impregnated fiber board may be secured to vertical concrete by nails in the first placed
concrete. The joint filler shall be coated on both faces with coal-tar pitch conforming to IS:216 or
bitumen grade conforming to IS:73 or IS:702.
i) Water stops shall not have any longitudinal joints and shall be procured and installed in
largest practicable lengths having a minimum number of transverse joints. The jointing
procedure shall be as per the manufacturer’s recommendations and shall be reviewed and
approved by the Project Engineer and Executing Agency. Suitable field splicing kit including
heater shall be used for this purpose. The edges shall be neatly crimped and bent to ensure
proper bond with the concrete.
195
ii) As Non-metallic Water Stops can be easily handled in very large lengths unlike metal strips,
transverse joints will be allowed only under unavoidable circumstances and with the specific
approval of the Project Engineer and Executing Agency. The method of forming these joints,
laps etc. shall be as specified by the Manufacturer and/or approved by the Project Engineer
and Executing Agency, taking particular care to match the centre and the edges accurately.
iii) Particular care shall be taken for the correct positioning of the water stops to prevent any
faulty installation, which may result in joint leakage.
Adequate provisions shall be made to support the water stops during the progress of work
and to ensure their proper embedment in the concrete. The symmetrical halves of the water
stops shall be equally divided between the concrete pours adjacent to the joints.
Max. Density and imperviousness of the concrete shall be ensured by thoroughly working in
the vicinity of joints. However, particular care should be exercised in use of vibrators in the
proximity of joints to avoid dislodging of the water stops.
iv) Splices
Splices in the continuity of intersections of runs of water stops shall be jointed as per
manufacturer’s stipulations depending on the type of water stops used. In case of a cross
section, overlapping must not be done but, instead factory made cross joint should be used.
It is essential that the material is not damaged during the splicing operation and that the
continuity of the entire water stops across the section be maintained.
v) Inspection
All water stops installations shall be subject to inspection and approval by the Project
Engineer and Executing Agency, before concreting operations, encasing water stops, are
performed.
 Sealing compound
When directed, the gap in joints shall be thoroughly cleaned and sealing compound laid as per
manufacturer’s specification and approved drawings. Primer shall be applied wherever required.
For reservoir/canal lining, procedure as stipulated under clause 9.0 of IS:5256-1969 shall be
followed.
 Metal cover strips
The metal cover strips shall be pinned (using stainless steel) at one end and slotted at the other end.
Exposed surface of mild steel shall be painted with two coats of approved anti-corrosive paint (as
per IS:2074) and/or bituminous paint. Welding of aluminium shall be in accordance with IS:2812.
196
3.1.52 Resilient pads:
The resilientpads shall be installed around the foundation or at other locations as shown on the
drawings. The pads shall be installed in position by sticking the same to the foundations by using
approved glue.
Waterproofing / damp proofing of underground concrete structures
3.1.53 Scope
This section of specification deals with the retirements of all works for completing water proofing
/ damp proofing of underground concrete structure. This shall include water retaining and basement
type structures.
As a general guidance, the provisions of IS: 6494 shall be followed unless otherwise mentioned.
The Concessionaire shall do the proper concreting so that concrete is water tight in itself without
any waterproofing treatment. The waterproofing treatment shall be provided in exceptional cases,
as additional precaution, as shown on the drawings or directed by the Project Engineer and
Executing Agency.
The work of waterproofing / damp proofing of underground concrete structures by course of

bitumen felt, blown bitumen or any other operations shall be entrusted by the Concessionaire to
one of the well known expert agencies approved by the Project Engineer and Executing Agency.
Actual type of waterproofing treatment to be provided for particular structure, shall be as shown
on the drawings or directed by the Project Engineer and Executing Agency.
3.1.55 Bitumen felt treatment
 Materials
a) The materials shall be in accordance with the relevant clauses of Technical specification for
properties, Storage and Handling of Common building materials
b) The bitumen felt shall conform to IS: 1322 and the workmanship to IS:1609 and IS: 3067.
The bitumen felt shall be hessian based. Bitumen primer shall conform to IS: 3384. The
bonding materials shall consist of blown type bitumen conforming to IS: 702 or residual
bitumen conforming to IS:73 or a mixture of the two, to withstand local conditions of
prevailing temperature gradient of surface. The Concessionaire shall satisfy the Project
Engineer and Executing Agency that the bonding materials proposed to be used are suitable
for the particular job.
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 Installation
a) Waterproofing / Damp proofing for horizontal surfaces, unless specified otherwise with two
layers of felt on which subsequently concrete shall be placed, shall be provided with the
following treatments :
i) A minimum of 12mm thick plaster 1:4 (1 cement : 4 sand) with waterproofing

admixture / additives over PCC
ii) One coat of bitumen primer @ 0.4 kg/Sqm min.
iii) One layer of hot applied bitumen @ 1.5kg/sq.m. min.
iv) One layer of self-finished felt (type - 3, grade II as per IS: 1322).
v) One layer of hot applied bitumen @ 1.5 kg/Sqm min.
vi) One layer of self-finished felt (type - 3, grade - II as per IS: 1322).
vii) One layer of hot applied bitumen @ 1.5 kg/Sqm min.
viii) A minimum of 12mm thick plaster 1:4 (1 cement: 4 sand ).
b) Water proofing / Damp proofing for other surfaces (including vertical) unless specified
otherwise, with two layers of felt shall be provided with following treatments:
i) One coat of bitumen primer @ 0.4 kg/Sqm min.

ii) One layer of hot applied bitumen @ 1.5 kg/Sqm min.
iii) One layer of self-finished felt (type - 3, grade - II as per IS: 1322).
iv) One layer of hot applied bitumen @ 1.5 kg/Sqm min.
v) One layer of self-finished felt (type - 3, grade II as per IS: 1322).
vi) One layer of hot applied bitumen @ 1.5 kg/Sqm min.
vii) A minimum 25mm thick plaster 1:4 (1cement: 4 stand).
viii) Half brick masonry work in cement mortar 1:4 (1 cement: 4 sand) using bricks of
class designation 75, unless otherwise specified.
3.1.56 Miscellaneous treatment
 Plastering treatment
After the side walls are constructed and allowed to undergo the specified curing, the surface of the
walls and the flooring should be made rough with a hacking tool, washed clean with water and wire
brushed so as to remove all the loose material, and a waterproof cement plaster 1:3 mix, with
suitable proportion of an integral waterproofing compound shall be applied in two coats, the first
coat being 12mm thick and the next 10mm thick. The second coat shall be applied after allowing a
time interval of at least 24 hrs for the first coat to harden. Hexagonal galvanized netting of 0.90mm
dia, 19 mm aperture size shall be used in the plastering. The netting shall be fixed with the help of
MS Screws, fixed with the help of fibrous plugs provided before application of first layer of plaster.
198
 Hot applied bitumen treatment
The external concrete of plastered surface shall be carefully cleaned, cured and allowed to dry for
some time before the application of a coat of hot bitumen of the industrial grade 85/25 conforming
to IS : 702 against ground water seepage. Rate of application of bitumen shall not be less than 1.7
kg/Sqm and it should be heated to about 120 C before application. Anti-stripping compound shall
be added. Anti-stripping and adhesion improving agent shall be 100% mixable in bitumen. The
stripping and adhesion improving agent shall be 100% mixable in bitumen. The stripping value
tested as per IS: 6241 should be nil when recommended quantity of anti-stripping compound is
mixed. Nominal mix proportion of the compound shall be 1 percent by weight of bitumen.
However, actual mix proportion shall be as per manufacturer's recommendation.
 Polymer modified cementitious coating treatment
a) Materials
i) Modified liquid polymer blend shall be a dispersion containing 100% acrylic based
polymer solids.
ii) Portland cement based dry powder
iii) Clean, fine specially prepared quartz sand approximately 0.6 mm size.
b) Mixing
The liquid polymer shall be stirred well and cement base powder shall then be added slowly
to make a slurry mix. For preparation of brush topping mix, quartz sand shall be added slowly
and mixed well till a homogenous mixture is obtained. The mix shall be used within half an
hour of the preparation. Addition of quartz sand may not be necessary, in case dry power
contains the same.
c) Properties of the coating
i) It must adhere to the wet surface

ii) It should develop adequate bond strength with the concrete surface, not less than 2 N /
Sqm
iii) Co-efficient of permeability shall be about 5 x 10 Cms
iv) Water absorption after continuous soaking shall not be more than 1%.
v) The materials shall be permeable under water vapor.
vi) The material shall be resistant to acids and alkalis’ present in the soil and underground
water with normal pH value between 4 and 14.
vii) The co-efficient of thermal expansion of the material shall be close to that of concrete.
d) Application
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The concrete surface shall be cleaned and made free from grease, oils or loosely adhered
particles. The surface shall be damp without any free water.
i) For slurry mix: a minimum of 2 coats shall be applied on the surface. The first coat
being applied when the surface is still damp and left to harden for 4 to 6 hours. After
4 to 6 hours of the application of second coat, it shall be finished by rubbing down with
a soft dry sponge. The coverage shall not be less than 1.1kg/sq.m in the 2 coats. A lap
of 75mm shall be provided at the joints.
The coating shall be air dried for 4 to 6 hours and, thereafter, cured for 7 days after the
application of last coat.
ii) For brush toping mix: This shall be applied in two coats. A primary coat of slurry mix
can also be first applied on the surface as first coat. After the coating has dried up, a
coat of brush toping mix shall be applied over it with a push broom or any other similar
brush. It shall be left in broom finished condition. The nominal thickness shall be
1.5mm and minimum thickness shall be 1.0mm. A lap of 75mm shall be provided at
the joints. It shall be ensured that no pinhole exists and re-brushing shall be done to
cover the pinholes if any.
The coating shall be air dried for 4 to 6 hours and thereafter cured for 7 days after
application of last coat.
3.1.57 Chemical injection treatment
Wherever shown on the drawing or directed by the Project Engineer and Executing Agency, min
12mm dia (N.B.) threaded nozzle of suitable length, shall be provided over the surface ad along the
construction joint line in a grid pattern at a spacing not exceeding 1.5m c/c before concreting
operation. Adequate precaution shall be taken to keep the nozzles plugged at both ends to prevent
them from getting closed by concrete.
For fixing of any nozzle in set concrete suitable size hole shall be drilled, preferably by using
repercussive hammer drill electrically operated, in grid pattern and grouting nozzle shall be fixed
in these holes.
After the nozzles are fully set, neat cement slurry admixed with water-soluble non-shrink
polymer/monomer based chemical shall be injected through the network of nozzles with low
pressure grout pumps at a pressure of about 2.0 kg/sq.cm. Water cement ratio of the slurry shall not
be more than 1:2. The resultant solution shall not have viscosity greater than 1:2 centipoises.
Plasticizing agent shall be added wherever required. The grouting shall be started at very low
pressure and increased gradually to a required pressure. The grouting shall continue till the hole
refuses to take any further grout, even at an increased pressure. Applied pressure shall not be more
200
than the designed strength of the concrete. After completion of grouting operation, the nozzles shall
be sealed properly to the satisfaction of the Project Engineer and Executing Agency.
Dismantling / demolishing work - RCC and PCC
3.1.58 Scope
This section of specification deals with the requirements of dismantling / demolishing RCC and /
or PCC work.
The dismantling implies, carefully taking up or down and removing without damage, this shall
consist of dismantling one or more parts of a structure. This includes chipping work, making holes/
opening etc in concrete members according to the required shape, size and profile at all elevations.
The term demolition implies, taking up or down or breaking up of a structure / member in part or
full as specified or shown on drawings or as directed by the Project Engineer and Executing
Agency.
In a structure / member, both dismantling and demolishing work may be involved. In such case,
the portion of work treated as demolishing shall be as shown on the drawing or as decided by the
All materials obtained from the demolition/dismantling work shall be the property of the Executing
Agency, unless otherwise specified.
All serviceable materials obtained, shall be separated out and stacked properly upto a lead of 500
meters and all unserviceable materials, rubbish etc shall be disposed off as directed by the Project
Engineer and Executing Agency..
The dismantling / demolishing operations shall be carried out in proper sequence so that the
serviceable material can be salvaged, without being damaged during the process of work.
Necessary propping, shoring and under pinning shall be provided for the safety of the adjoining
work or property which is to be left intact, before dismantling / demolishing work
3.1.60 Safety
All demolition work shall be carried out in conformity with the local safety regulations, extreme
caution being exercised to avoid damage to the work and the equipment, which are to be left intact.
Necessary precautions shall be taken to keep the dust nuisance down. Safety requirements in IS:
4130 shall also be followed.
201
As and where necessary, the dismantled / demolished materials shall be lowered to the ground and
not thrown and then properly stacked as directed by the Project Engineer and Executing Agency.
Wherever required, temporary enclosures shall be erected to minimize the dust or moisture
infiltration.
Cement additives / admixtures in concrete
3.1.61 Scope
This section of specification deals with the requirements of furnishing, placing and mixing cement
additives / admixtures, in all kinds of cement concrete, (plain or reinforced) for all kinds of
structures at all levels.
The Concessionaire shall furnish all labour and equipment to place and mix waterproofing cement
additive and cement plasticizer in concrete of any grade and cement mortar. Thereafter he shall
carry out the work as specified earlier in relevant clauses of this specification for concrete and
hence complete the work as indicated on the drawing and as per the specification listed hereunder.
Waterproofing additive and other types of admixtures shall be as far as possible, free from
aggressive chemical like chloride, sulphide etc., which can cause corrosion of steel reinforcement
in RCC.
The Concessionaire shall have the services of the manufacturer's supervisor, at no extra cost to the
Executing Agency, to supervise the work, if directed by the Project Engineer and Executing
Agency.
Admixtures in concrete for promoting workability, improving strength, entraining air or for similar
purposes may be used only after the written permission from the Project Engineer and Executing
Agency, is obtained. Addition to admixtures shall not reduce the specified strength or durability
of concrete in any case. The admixtures shall conform to IS: 9103 and shall be of proven make and
from a reputed manufacturer. Calcium chloride shall not be permitted to be used other than in mass
(plain) concrete works.
3.1.63 Materials
Waterproof cement additive shall conform to IS: 2645 and shall be of proven make and from a
reputed manufacturer.
Admixtures in concrete shall conform to IS: 9103 and shall be of proven make and from a reputed
manufacturer. In addition, for plasticizer cum waterproofing compound materials shall meet the
permeability requirements as per IS: 2645. Similarly, for plasticizer cum retarder admixture
material shall satisfy the setting time requirements of retarder and other properties of plasticizer as
per IS: 9103.
202
3.1.64 Mixing
Admixtures / waterproofing additive shall be used at the rate specified by the manufacturer or as
indicated on the drawings and shall be mixed with water, as required by the Project Engineer and
Executing Agency. Samples of concrete in which admixture and / or waterproofing cement additive
is added shall be tested for water proofness, workability, compressive strength, water absorption,
density, setting time, etc., the results shall conform to relevant IS specifications.
Table - 4: Frequency of sampling and testing
Sl. Nature of test/ Method of No. of samples
Remarks
No. characteristics test & frequency of test
1. Coarse aggregates
a) Particle size & shape IS:2386(Pt.1) One per 100 cum. or Result to be as per the
part thereof or change requirement of design mix,
of source whichever is subject to variations within
earliest the limits specified in
relevant Indian Standards.
b) Moisture content IS:2386(Pt.3) Once for each stack of Accordingly water content
100 cum. or part of the concrete shall be
thereof except during adjusted.
monsoon when this has
to be done every day
before starting of the
work.
c) Specific gravity, IS:2386(Pt.3) Once in 12 weeks or These tests shall be carried
density, voids, change of source out while establishing
absorption. whichever is earlier design mix and results to be
intimated.
d) Mechanical properties, IS:2386(Pt.4) Once per source Acceptance norms shall be
crushing value, as per IS:383
abrasion value and
impact value.
e) Soundness IS:2386 (Pt.5) Once per source Acceptance norms shall be
as per IS:383.
f) Reaction with alkali. IS:2386 (Pt.7) Once per source These tests shall be carried
out while establishing
design mix and result to be
intimated. Acceptance shall
be as per IS:2386 (Pt.7).
g) Flakiness and petro- IS:2386 This is to be done once These tests shall be carried
graphic examinations and should be repeated out while establishing
in case the source is design mix and results to be
changed. intimated.
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Remarks
h) Deleterious materials IS:2386 (Pt.2) Once per source Results should be within the
limit as specified in relevant
Indian Standards and in this
Specification.
2. Fine aggregates /
sand
a) Particle size and shape. IS:2386 (Pt.1) One per 100 cum. or Should be as per the
part thereof or change requirement of design mix,
of source, whichever is subject to variation within
earlier. the limit as specified in
relevant IS Codes.
b) Specific gravity, IS:2386 (Pt.3) Once in 12 weeks or These tests will be carried
density, voids, change of source out while establishing
adsorption and whichever is earlier design mix and results to be
bulking. intimated.
c) Bulk age, moisture IS:2386 (Pt.3) To be done every day Volume of sand and weight
content (Routine test) before start of work. of water shall be adjusted as
per bulk age and moisture
content.
d) Silt, clay deleterious IS:2386 (Pt.2) Once per source and to Volume of sand and weight
materials, organic be repeated, if source is of water shall be adjusted as
impurities. changed. per bulk age & moisture
content.
e) Soundness and IS:2386 (Pt. 5 Once per source. Acceptance norms shall be
Petrographic & 8) as per IS:383.
examination.
f) Mortar making IS:2386 (Pt.6) -do- Acceptance norms shall be
properties. as per IS:383.
g) Reaction with alkali. IS:2386(Pt.7) Once per source Acceptance norms shall be
as per IS:383 and IS:2386
(Pt.7).
3. Cement
a) Setting time IS:4031 One sample of each Acceptance norms shall be
received from stores. as per relevant Indian
Standard
b) Compressive Strength IS:4031 -do- -do-
4. Water
Harmful substances, IS:3025, Once a month for each Acceptance norms shall be
pH value, initial setting IS:4031 & source as per Cl.4.3 of IS:456-
time, compressive IS:516 1978.
strength.
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Remarks
5. Concrete
a) Workability (Slump IS:1199 One sample every two Acceptance value shall be
and compaction factor) hours from every as per Cl. 6.1 of IS:456-
mixing plant. 1978.
b) Crushing Strength IS:516 i) As per Cl.14.2.2 of Acceptance criteria shall be
IS:456-1978 for as per Cl.15 of IS:456-1978.
initial period A minimum of 3 (Part-7)
ii) One sample of six specimens shall be tested
cubes per 150 cum for 28 days strength.
or part thereof for
mass concrete for
subsequent period.
c) Water-cement ratio IS:119 At random at the time According to mix design
of batching
d) Cement Content IS:1199 -do- -do-
e) Finished dimensions Physical All structures Acceptance as per
measurement Specification
6. Form work Visual Each member Any staging intended for
a) Staging (Durability use shall be approved by the
strength & Project Engineer and
soundness of Executing Agency for its
staging, joints, durability and strength
adequacy of its
foundation and
specific level)
After erection of staging,
nominated representatives
of Project Engineer and
Executing Agency shall
check the soundness of the
staging as a whole, its joints,
adequacy of its foundation
and the specific levels.
b) Shuttering
i) Materials Visual Random Formwork materials shall
be strictly as per
specifications and approved
of the Project Engineer and
Executing Agency.
Materials for formwork
shall be unwrapped,
205
Remarks
thoroughly clean and
without broken or damaged
edges either due to
repetitive use or otherwise.
Oiling of for m work before
concreting shall be resorted
to.
ii) Joints Visual Random Joints shall be leak proof to
avoid loss of liquid
iii) Dimensions Physical Each member and Tolerance as per
and plumb measurement before every lift. Specification
7 Reinforcement
a) Placement Visual each The bar bending schedule
with the necessary hooks,
laps, covers, spacers and
chairs shall be 100%
checked for all concreting
works before start of the
work.
b) Cutting tolerance Physical Random Tolerance shall be as per
measurement specification.
Slab on grade
3.1.65 Scope
This section of specification deals with carrying out the work of “slab on grade”. In all medium
duty industrial floors
The Concessionaire shall furnish all material/ labour and equipment. The specifications covered
under section C-3, sub section 1 to 13 for cast in situ concrete and allied works shall generally be
applicable unless otherwise specified here under.
The work includes right from preparation of sub grade to completing and curing slab on grade in
all respects to the satisfaction of the Project Engineer and Executing Agency.
3.1.67 Materials
206
(a) Materials for filling shall be crushed stone dust, sand or other inorganic materials and they
shall be clean and free from shingle, salts, organic matters, roots and excessive amount of
sod, concrete or any other foreign substances which could harm or impair the strength of the
substructure in any manner.
(b) Stones for Granular sub base shall be broken stones to gauge not exceeding 63 mm and shall
be free from dust, organic matters etc.
(c) Maximum size of 40 mm stone aggregate shall be used for concrete.
(d) Cement shall be ordinary Portland cement conforming to IS:269,Grade 43
(e) Admixtures in concrete for improving workability, strength etc may be used only after the
written permission from the Project Engineer and Executing Agency.
(f) Water shall be clean, free from injurious matters. Potable water is generally considered
satisfactory.
(g) Reinforcing steel bars shall conform to grade 1 of IS:432 (part 1)
(h) Polysulphide sealant shall conform to IS 12118 Gun Grade.
(i) Concrete curing compound shall be CONCURE WB of M/s. Fosroc Chemicals (India) Ltd.,
or equivalent.
3.1.68 Laying of slab on grade
i) Uneven (but fairly level) sub grade shall be dressed, leveled by necessary Excavation /
Scraping / Filling, watered, rolled by 10T roller and consolidated to desired level.
ii) On consolidated sub grade, two layers of granular sub base each of 75 mm thickness shall
be laid Total consolidated thickness of sub base shall be 150 mm. Refer specification No.C-
1.6.0 - Granular Sub Base (Hard core)
iii) On consolidated sub base water proof paper shall be placed with minimum 150mm overlaps
on all sides.
iv) Concrete grade M20, 150 mm thick shall be poured in strips as per drawing and as directed
by the Project Engineer and Executing Agency.
The strips shall be prepared by placing formwork in straight line and level. Each strip may
be of size 4 metre wide x 20 metre long alternate strips shall be cast by leaving 24 hours
interval in between.
Form work shall be strong enough to hold the screed vibrator.
The concrete shall be vibrated by screed vibrator / surface vibrator and when it becomes
touch dry it shall be machine trowel led to smooth uniform level surface. Ramp surfaces shall
then be “Broom Finished”.
Under no circumstances dry cement or cement slurry shall be separately spread on concrete
at any time.
207
Special care shall be taken to pour and vibrate the concrete along the form work to avoid any
segregation of aggregate and honey combing.
v) 24 hours after concreting, the form work shall be removed and immediately the grooves of
size 10mm x 50mm as shown on the drawing shall be cut in concrete at an interval of about
4.0 metres or as shown on the drawing.
The grooves shall be cleaned and concrete surface shall then be sprayed by water based
concrete curing compound as specified. The grooves shall be filled up by poly sulphide
sealant after fourteen days.
vi) Dowels shall be provided along transverse and longitudinal construction joints as shown on
the drawing.
vii) Any expansion / contraction joints in slab on grade shall be provided at locations and as per
the details indicated on the drawing.
All finished surface shall be smooth, uniform and at desired line and level within a tolerance of ±
3.0 mm. It shall be free from cracks and warping.
208
Sub-section - C4
Technical specification for masonry and allied works
209
Sub-Section - C4
Technical specification for masonry and allied works
Contents
4.1 Scope ............................................................................................................................................. 211

4.4 Brick masonry ............................................................................................................................... 212
4.5 Fly ash brick masonry ................................................................................................................... 212
4.6 Stone masonry............................................................................................................................... 216
4.7 Mouldings and cornices ................................................................................................................ 220
4.8 Plinth protection ............................................................................................................................ 220
4.9 Damp Proof Course (DPC) ........................................................................................................... 221
4.10 Dismantling and demolition .......................................................................................................... 222
4.11 Sampling testing and quality control ............................................................................................ 223
210
Section - C4: Technical specifications for masonry and allied works
4.1 Scope
This section of the specification covers furnishing, installation including handling, transportation,
batching, mixing, laying, scaffolding, centering, shuttering, finishing, curing, protection and
repairing till handing over of brick masonry and allied works including DPC, plinth protection and
dismantling.
The Concessionaire shall furnish all skilled and unskilled labour, plant, equipment, scaffolding,
materials, etc. required for complete execution of the work in accordance with the drawings and as
described herein and/or as directed by the Project Engineer and Executing Agency.
All workmanship shall be in accordance with the latest standards and best possible practice.
Masonry work shall be true to line & level as shown on drawings. All such masonry shall be tightly
built against structural members and bonded with dowels, anchors, inserts, etc, as shown on the
drawings.
The Concessionaire shall carry out all works for settling out the building lines, locating the co-
ordinates and establishing the reduced levels (RL’s) on the basis of reference grid lines and bench
mark, which shall be furnished by the Executing Agency, at one or more locations.
Any approval, instructions, permission, checking, review, etc. whatsoever by the Project Engineer
and Executing Agency shall not relieve the Concessionaire of his responsibility and obligation
regarding adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.
All applicable standards, acts and codes of practice referred to shall be the latest editions including
all applicable official amendments and revisions. A complete set of all these documents shall
generally be available at site, with the Concessionaire.
In case of conflict between this specification and those (IS Standards, Codes etc.) more stingent
shall prevail.
IS:1127 Recommendations for Dimensions and Workmanship of Natural Building Stones

for Masonry Work.
IS:1597 Code of practice for construction of Stone Masonry.
IS:1905 Code of Practice for Structural Safety of Buildings - Masonry walls.
IS:2116 Specification for sand for masonry mortars.
211
IS:2185 Specification for Hollow cement concrete blocks
IS:2212 Code of Practice for Brickwork.
IS:2250 Code of Practice for preparation and use of masonry mortar.
IS:2572 Code of Practice for construction of Hollow concrete block masonry
IS:3414 Design and installation of joints in buildings.
IS:3696 Safety code for scaffolds and ladders.
IS:4130 Safety code during demolition of buildings.
IS:4326 Code of practice for earthquake resistant design and construction of buildings
IS:12894 Fly ash lime bricks specifications.
SP:20 Explanatory hand book on masonry code.
4.4 Brick masonry
4.4.1 Materials
Properties of common building materials for the construction of brick masonry, viz. burnt clay
bricks, sand lime and cement shall be in accordance with the technical specification for ‘Properties,
Storage and Handling of Common Building Materials’ (vide Mode C2). Besides clay bricks, other
type of bricks like, fly ash-lime bricks cured by autoclave process shall also be used, whenever
specified, or shown on the drawing.
4.5 Fly ash brick masonry
4.5.1 Materials
Properties of common building materials for the construction of brick masonry, viz. fly ash bricks,
sand lime and cement shall be in accordance with the technical specification for ‘Properties, Storage
and Handling of Common Building Materials’ (vide Mode C2). Besides fly ash bricks, other type
of bricks like, fly ash-lime bricks cured by autoclave process shall also be used, whenever specified,
or shown on the drawing.
4.5.2 Mortar
IS: 2250 shall be followed as general guidance for preparation and use of mortar. Only cement &
Fly ash-sand mortar shall be used. Lime shall be added for composite mortar with specific approval
of the Project Engineer and Executing Agency.
Unless otherwise specified, mortar for brickwork having one or more brick thickness shall be 1 part
cement & fly ash (20% replacement ratio of cement with fly ash): and 6 parts sand by volume.
Mortar for half-brick thick walls shall be 1 part cement & fly ash (20% replacement ratio of cement
with fly ash): and 4 parts sand by volume. Richer mix proportion shall be used, whenever specified
or as per design requirement. Mortar shall meet the compressive strength requirement as per IS:
2250 and IS: 1905.
212
Sand shall conform to IS: 2116. Grading of sand when tested as per IS: 2386 shall be as specified
in Table -1.
Table 1: Grading of sand for use in masonry mortars

IS sieve designation IS:460 (Part – I) Percentage passing by mass Method of test
4.75mm 100 IS:2386
2.36mm 90 to 100 (Part-I)
1.18mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15
Sand, whose grading falls outside the specified limits due to excess or deficiency of coarse or fine
particles, may be processed to comply with the standard by screening through a suitably sized sieve
and/or blending with required quantities of suitable sizes of sand particles. Based on test results
and in the light of practical experience with the use of local materials, deviation in grading of sand
given in Table-1 may be considered by the Project Engineer and Executing Agency. The various
sizes of particles of which the sand is composed, shall be uniformly distributed throughout the
mass. The required grading may often be obtained by screening and/or by blending together either
natural sands or crushed stone screenings, which are by themselves of unsuitable grading.
Cement, fly ash (20% replacement ratio of cement with fly ash): and sand shall be thoroughly
mixed dry in a mechanical mixer and water shall then be added to obtain a mortar of the consistency
of a stiff paste, care being taken to add just sufficient water for the purpose. Water shall be clean
and free from injurious amount of deleterious matter such as oil, acid alkali, salt and vegetable
growth. Hand mixing may be allowed by the Project Engineer and Executing Agency on clean
approved platform in special cases only. Mortar shall be used as soon as possible after mixing,
before it begins to set and preferably within 30 minutes after water is added to the dry mixture.
Mortar unused for more than 30 minutes shall generally be rejected and removed from site of work.
However, the Project Engineer and Executing Agency may allow the use of mortar upto 2 hours.
Surplus mortar droppings while laying masonry, if received on a surface from dirt, may be mixed
with fresh mortar if permitted by the Project Engineer and Executing Agency, where direct for
addition of extra cement and this shall be implemented.
4.5.3 Laying
IS:2212 shall be followed as general guidance for construction of brick masonry Vat/tank of
suitable size shall be provided by the Concessionaire for soaking of bricks. Bricks shall be soaked
in water before use for a period generally not less than 6 hours so that the water just penetrates the
whole depth of the bricks. Bricks shall be laid in by hand and not thrown inside the tank. Bricks
shall be taken out sufficiently in advance so that these are skin dray at the time of laying.
213
Bricks shall be laid in English Bond unless otherwise specified. Half or cut bricks shall not be used
except where necessary to complete the bond. Closers in such cases shall be cut to the required size
and used near the ends of the walls, next to quoin headers.
Bricks shall be laid generally with frogs upwards. A layer of mortar shall be spread on the full
width and over a suitable length of the lower course. Each brick shall be properly bedded and set
home (in position) by gently tapping with the trowel handle or with a wooden mallet. It’s inside
face shall be buttered with mortar before the next brick is laid and pressed against it. On completion
of a course, all vertical joints shall be fully filled from the top with mortar. The thickness of joints
shall be kept uniform and shall not exceed 10 mm. Bricks shall be so laid that all joints are full of
mortar.
All face joints shall be raked to a minimum depth of 15 mm by raking tools during the progress of
brickwork, when the mortar is still green, so as to provide proper key for the plaster or pointing to
be done. When plastering or pointing is not required to be done, the joints shall be struck flush and
finished at the time of laying.
Brickwork in walls shall be taken up truly plumb. All courses shall normally be laid truly horizontal
unless indicated to be laid on slope and all vertical joints shall be truly vertical. Vertical joints in
alternate courses shall come directly one over the other. Brick wall shall be construed with atleast
one plain face with proper alignment.
All connected brickwork shall be carried up simultaneously and no portion of work shall be left
more than one metre below the rest of the work. Where this is not possible, in the opinion of the
Project Engineer and Executing Agency, the work shall be raked back according to bond (and not
toothed) at an angle not steeper than 45 deg. The work done per day should not be more than one
metre height
All iron fixtures, pipes, water outlets, holdfasts for doors and windows, etc. which are required to
be built into the brickwork shall be embedded in their correct position in mortar or cement concrete
as the work proceeds as per directions of the Project Engineer and Executing Agency.
All brickwork shall be built tightly against columns, floor slabs or other structural parts and around
door and window frames with proper distance to permit caulked joint. Where drawings indicate
that structural steel columns and spandrel beams are to be partly or wholly covered with brickwork,
the bricks shall be laid closely against all flanges and webs with all spaces between the steel and
brickwork filled solid with mortar not less than 10mm in thickness.
The top courses of all plinth, parapet, steps and top wall below CRC shall be laid with brick on
edge (other than modular size bricks) unless otherwise specified. Care shall be taken that the bricks
forming the top courses and ends of walls are properly radiated and keyed into position as shown
on the drawings.
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Scaffolding shall be strong enough to withstand all the dead, live and impact loads which are likely
to come upon it. It shall also be so designed as to ensure the safety of the workmen using them.
For all brick masonry except for exposed brickwork, single scaffolding shall be permitted. In such
cases, the inner end of the horizontal scaffolding pole shall rest in a hole provided only in header
course for the purpose. Only one header for each pose shall be left out. Such holes for scaffolding
shall, however, not be allowed in pillars/columns less than one metre in width. The holes left in
masonry works for scaffolding purposes shall be filled and made good before plastering.
In case of joining old brickwork with new brick work, the old work shall be toothed to the full
width of the new wall and to the dept of quarter of a brick in alternate courses. It shall be cleaned
of all dust, loose mortar, etc., and thoroughly wetted before starting new brick work. Thickness of
each course of new work shall be made equal to the thickness of the corresponding course of the
old work by adjusting thickness of horizontal mortar joints.
The face of the brickwork shall be cleaned on the same day on which brickwork is laid and all
mortar dropping removed promptly.
Template (bed-block) of plain or reinforced cement concrete shall generally be provided to support
ends of RCC beams. Top surface of the wall shall be suitably treated as per direction of the Project
Engineer and Executing Agency so as to minimise the friction to movement of the concrete slab
over the bearing.
Brickwork shall be protected from rain by suitable covering when the mortar is green. Masonry
work shall be cured by keeping it constantly moist on all faces for a minimum period of seven days.
Brickwork carried out during the day shall be suitably marked indicating the date on which the
work is done so as to keep a watch on the curing period.
4.5.4 Half brick masonry
The work shall be done in the same manner, as mentioned in 4.03 except that all course shall be
laid with stretchers. In cases where reinforcement is considered necessary from structural
consideration, 2 nos. 8 mm dia bars shall be provided generally at every 4th layer of bricks or as
specified on the drawings. Before laying reinforcement, it shall be cleaned of rust and loose flakes
with a wire brush. They shall be securely anchored at their ends where the partitions bond. Half the
mortar thickness for the bedding joint shall be laid first and then 8mm dia bars laid straight out near
each face of the brickwork maintaining a side cover of 12mm mortar. Subsequently the other half
of the mortar thickness shall be laid covering the reinforcement fully.
4.5.5 Exposed brickwork
Exposed brickwork i.e. brickwork is superstructure which is not covered by plaster shall be as
shown on the drawings and shall be done by specially skilled masons. All courses shall be laid truly
horizontal and all vertical joints shall be truly vertical. Vertical joints in alternate courses shall
215
come directly one over the other. Thickness of brick courses shall be kept uniform and for this
purpose wooden straight edge with graduations indicating thickness of each course including joint
shall be used. The height of window sills, bottom of lintels and other such important points in the
height of the wall shall be marked on the graduated straight edge. Masons must check workmanship
frequently with plumb, spirit level, rule and string.
For all exposed brick work, double scaffolding having two sets of vertical supports shall be
provided. The supports shall be sound and strong, tied together with horizontal pieces over which
scaffolding planks shall be fixed.
If face bricks are specified on the drawings, the brickwork shall be in composite work with face
bricks on the exposed face and balance in standard bricks, but maintaining the bond fully. Where
face bricks are not specified, bricks for the exposed face shall be specially selected from available
stack of bricks. All exposed brickwork on completion of work shall be rubbed down, washed clean
and pointed as specified. Where face bricks are used, carborundum stone shall be used for rubbing
down.
4.5.6 Reinforcing anchorage
For external walls, the anchorage in the form of flats or rods from spandrel beams and columns and
any other anchoring and reinforcement as shown on the drawing shall be adequately embedded in
the masonry.
4.6 Stone masonry
Rubble stone masonry which is commonly used in stone work has been covered under this
specification. Details of construction for Random Stone Masonry (uncoursed) and Coursed Rubble
Masonry (first and second sorts) are given in the following clauses. IS: 1597 shall be followed as
general guidance for construction of stone masonry
4.6.1 Stone masonry
The stone shall be of the type specified, such as granite, sand stone, quartzite and /or best locally
available stone which shall be subject to approval of the Project Engineer and Executing Agency.
It shall be obtained only from an approved quarry. Colour of the stone shall be as shown on the
drawings or approved by the Project Engineer and Executing Agency. It shall be hard, sound,
durable and free from decay, weathering. It shall also be free from defects like cavities, cracks,
sand holds, flaws, veins, patches of soft and loose materials, etc. Stones with round surface shall
not be more than 5 percent when tested in accordance with IS: 1124. The minimum crushing
strength of stone shall be 200 kg/sq cm unless otherwise specified.
4.6.2 Size of stone
216
Normally, stones used should be small enough to be lifted and placed by hand. The length of stone,
shall not exceed three times the height and the breadth on base shall not be greater than three fourth
of the thickness of wall not more than 15 cm. The height of stone may be upto 30 cm.
4.6.3 Mortar
Unless otherwise specified, mortar for stone masonry shall be 1 part of cement & fly ash (20%
replacement ratio of cement with fly ash): and 6 parts sand by volume. Properties, preparation and
use of mortar shall be same as specified for brick masonry work.
4.6.4 Dressing of stone
The dressing of stone shall be as specified below for individual types of masonry work and it shall
also conform to the general requirements for stone covered in IS:1129.
a) For Random Rubble Stone Masonry, stone shall be hammered ---- the face, the sides and the
beds to enable it to come into close with the neighbouring stone. the bushing on the face shall
be than 4 cm on an exposed face, and 1 cm on a face, to
b) For coursed Rubble Masonry (First sort) Face stones, shall dressed on all beds, and joints, so
as to give them approx. angular shape.
4.6.5 Laying
a) Random rubble masonry
All stones shall be wetted before use. The wall shall be carried up truly plumb or to the
specified batter. Every stone shall be carefully fitted to the adjacent stones, so as to form neat
and close joints. Stones may be brought to level courses at plinth, window sills and roof level.
Levelling up shall be done with concrete comprising of one part of mortar (used for the
masonry) and two parts of graded stone aggregate of 20 mm nominal size. The bond shall be
obtained by fitting in closely, the adjacent stones and by using bond stones.
Face stones shall extend and bond well into the backing. These shall be arranged to break
joints as much as possible, and to avoid long vertical lines of joints, the hearting or interior
filling of the wall shall consist of rubble stones which may be of any shape but shall not pass
through a circular ring of 15 cm inner diameter. Thickness of these stones in any direction
shall not be less than 10 cm. These shall be carefully laid, hammered down with a wooden
mallet into the position and solidly bedded in mortar. Clips and spells of stone shall be used
where necessary to avoid thick mortar beds or joints and at the same time ensuring that no
hollow spaces are left any where in the masonry. The hearting shall be laid nearly level with
facing and backing except that at about one metre intervals, vertical ‘plumb’ projecting about
15 cm to 20 cm shall be firmly embedded to form a bond between successive courses. The
chips shall not be used below the hearting stone to bring these upto the level of face-stones.
217
The use of chips shall be restricted to the fillings of interstices between the adjacent stones
in hearting and these shall not exceed 20% of the quantity of stone masonry. The masonry in
a structure shall be carried regularly. Where the masonry of one part has to be delayed, the
work shall be raked back at an angle not steeper than 45 deg. Toothing in masonry shall not
be permitted.
Bond or through stones running right through the thickness of walls shall be provided in walls
upto 60 cm thick and in case of walls above 60 cm thickness, a set of two or more bond stones
overlapping each other by atleast 15 cm shall be provided in a line from back to back.
In case of highly absorbent type of stones (porous lime stone and sand stone etc.) the bond
stone shall extend about two third into the wall. Through stones in such cases may give rise
to damp penetration and therefore, for all thickness of such walls, a set of two or more bond
stones overlapping each other by atleast 15 cm shall be provided.
Where bond stones of suitable length are not available, cement concrete block of mix 1:3:6
(with 20mm nominal size graded stone aggregate) shall be used. Atleast one bond stone or a
set of bond stones shall be provided for every 0.5 sq m of the wall surface. All bond stones
in stone masonry shall be marked suitably as directed by the Project Engineer and Executing
Agency.
The quoins shall be selected stones, neatly dressed with the hammer or chisel to form the
required angle, and laid header and stretcher in the alternate layers. Volume of these stones
shall not be less than 0.03 cu m.
Stones shall be so laid that all joints are fully packed with mortar and chips. Face joints shall
not be more that 20mm think. When plastering or pointing is not required to be done, the
joints shall be struck flush and finished at the time of laying. Otherwise the joints shall be
raked to a minimum depth of 20 mm by raking tool during the progress of work, when the
mortar is still green.
Single scaffolding having one set of vertical support shall be allowed. Masonry work shall
be kept constantly moist on all faces for a minimum period of seven days. Green work shall
be protected from damage, mortar dropping and rain during construction.
b) Coursed rubble masonry (First Sort)
All stones shall be wetted before use. The walls shall be built up truly plumb or to specified
batter. All courses shall be laid truly horizontal and all vertical joints shall be truly vertical.
The height of each course shall not be less than 150 mm nor more than 300 mm. Every stone
shall be carefully fitted to the adjacent stones, so as to form neat and close joints. Face stones
shall be laid in alternate header and stretcher fashion. No face stone shall be less in breadth
than its height and at least one third of the stones shall tail into the work for length not less
than twice their height. These shall be so arranged as to break joints by 7 atleast 75 mm. Each
218
face stone shall be of the same height in any given course. The bond shall be obtained by
fitting in closely the adjacent stones and by using bond stones.
Stones shall be laid with grains horizontal so that the load is transmitted along the direction
of the maximum crushing strength.
The hearting or the interior filling of the wall shall consist of stones carefully laid on their
proper beds in mortar; chips and spalls of stone being used where necessary to avoid thick
beds or joints of mortar and at the same time ensuring that no hollow spaces are left anywhere
in the masonry. The chips shall not be used below the hearting stone to bring these upto the
level of face stones. The use of chips shall be restricted to the filling of interstices between
the adjacent stones in hearting and these shall not exceed 10% of the total volume of stone
masonry. All bed joints shall be horizontal and all side joints vertical. All joints shall be fully
packed with mortar. Face joints shall not be more than 10 mm thick. When plastering or
pointing is not required to be done, the joints shall be struck flush and finished at the time of
laying. Otherwise, the joints shall be raked to a minimum depth of 20mm by raking took
during the progress of work, when the mortar is still green.
Stone may be brought to level courses at plinth, window sills and roof level. Levelling up at
plinth level, window sills and roof level shall be done with concrete comprising of one part
of the mortar (use for the masonry) and two parts of graded stone aggregate of 20mm nominal
size.
The masonry in a structure shall be raised up uniformly and regularly but where breaks are
unavoidable, the work shall be raked back at angle not steeper than 45 deg. Too things shall
not be allowed. Masonry on any day should not be raised by more than 1 metre in height.
Bond or through stones running right through the thickness of walls shall be provided in walls
upto 600 mm thick and in case of walls above 600 mm thickness, a set of two or more bond
stones overlapping each other by atleast 150mm shall be provided in a line from face to back.
In case of highly absorbent types of stones (porous limestone and sand stone etc.) the bond
stone shall extend about two-third into the wall. Through stones in such cases may give rise
to damp penetration. Therefore, for all the thickness of such walls, a set of two or more bond
stones overlapping each other by atleast 150mm shall be provided.
Where bond stones of suitable lengths are not available, cement concrete blocks of 1;3:6 mix
(1cement : 3 sand : 6 graded stone aggregate 20mm nominal size) shall be used.
A bond stone or a set of bond stones shall be inserted 1.5 to 1.8 metres apart, in every course.
All bond stones shall be suitably marked during construction for subsequent verification and
shall be staggered in subsequent layers. The quoins shall be of selected stones, neatly dressed
with the hammer or chisel to form the required angle. These shall be of the same height in
which these occur. These shall be at least 450 mm long and shall be laid stretchers and
219
headers alternately. These shall be laid square on the beds, which shall be rough chisel
dressed to a depth of atleast 100 mm. In case of exposed work, these stones shall have a
minimum 25mm wide chisel drafts at four edges, all the edges being in the same plane. Single
scaffolding having one set of vertical support shall be allowed. The supports shall be sound
and strong, tied together by horizontal scaffolding member may rest in a hole provided in the
masonry. Such holes, however, shall not be allowed in pillars less than one metre in width.
The holes left in masonry work for supporting scaffolding shall be filled and made good with
cement concrete 1:3:6 (1 cement : 3 sand : 6 stone aggregate 20 mm nominal size)
Masonry work shall be kept constantly moist on all faces for a minimum period of seven
days. Green work shall be protected from rain by suitable covering. The work shall also be
suitably protected from damage, mortar dropping and rain during construction.
c) Coursed rubble masonry (second sort)
Laying of this type of masonry shall be in the same manner as First Sort masonry described
above except for the following:
The use of chips for filling of interstices of adjacent stones in hearting shall not exceed 15%
of the total volume of stone masonry, and stone in each course need not be of the same height,
but more than two stones shall not be used in the height of a course. Face joints shall not be
more than 20mm thick.
4.7 Mouldings and cornices
The bricks or stones shall be cut and dressed to the required shape as shown on architectural
drawings. If no subsequent finish is envisaged, these shall be rubbed to correct profile with
carborundum stone.
4.8 Plinth protection
Plinth of buildings shall be protected with brick on edge paving of minimum 750mm width unless
otherwise shown on the drawings. The treatment shall consist of laying bricks conforming to class
50 (min.) of IS:1077 in cement mortar 1:6 (1 cement & fly ash (20% replacement ratio of cement
with fly ash): : 6 sand) over a 75 mm thick bed of dry graded brick aggregate, 40mm nominal size,
grouted with sand. the top shall be finished with 1:3 cement mortar pointing (1 cement & fly ash
(20% replacement ratio of cement with fly ash):: 3 sand). Plinth protection shall be laid with a
minimum outward slope of 1 in 50. The brick aggregate shall be well graded, broken from well
burnt or slightly over burnt and dense brick bats. It shall be homogeneous in texture, roughly cubical
in shape, clean and free from dirt or any other foreign matter.
The ground shall first be prepared to the required, slope around and building. The high portions of
the ground should be cut down, hollows and depressions filled upto the required level from the
excavated earth and rammed so as to give uniform outward slope. The bed shall be watered and
220
rammed and heavy iron square rammers. Surplus earth, if any, shall be disposed off beyond a lead
of 50 m or as directed by the Project Engineer and Executing Agency.
Over this, 75mm thick bed of dry brick aggregate of 40mm nominal size shall be laid with a
minimum outward slope of 1 in 50. Aggregates shall be carefully laid and packed, bigger sized
being placed at the bottom. The brick aggregates shall be consolidated dry with heavy iron
rammers.
The aggregates shall then be grouted evenly with sand at the rate of 0.06 cubic metre per square
metre area, adequately watered to ensure filling of voids by sand and again rammed with heavy
iron rammers. The finished surface shall give uniform appearance. After the sub grade has been
compacted thoroughly, brick flooring with bricks of specified strength in cement mortar 1:6 (1
cement & fly ash (20% replacement ratio of cement with fly ash): 6 sand) shall be laid. The soaking
of bricks shall be done as per the relevant standard. The bricks shall be laid on edge in Diagonal /
herring Bone Bond or other pattern as specified or as directed by the Project Engineer and
Executing Agency. Bricks shall be laid on 12mm thick mortar bed and each brick shall be properly
bedded and set home by gentle tapping with handle of trowel or wooden mallet. It’s inside face
shall be buttered with mortar before the next brick is laid and pressed against it. On completion of
the portion of flooring, the vertical joints shall be fully filled from the top with mortar. The surface
shall present a true plain surface with the required slope.
The point shall be done in cement mortar 1:3 (1cement & fly ash (20% replacement ratio of cement
with fly ash): 3 sand). The mortar shall be pressed into the joints and shall be finished off flush and
level with the edges of the bricks so as to give a smooth appearance. The edges shall be neatly
trimmed with a trowel and a straight edge the mortar shall not spread over surface of the masonry.
Brick flooring and pointing shall be kept wet for a minimum period of seven days. These shall be
protected from rain by suitable covering when the mortar is green.
4.9 Damp Proof Course (DPC)
All walls in a building shall be provided with a damp proof course generally immediately below
the underside of the ground floor or as shown on the drawings. This shall run without break
throughout the length of the wall, even under door or other openings.
Damp proof course shall be 50 mm thick (unless, otherwise specified) consisting of cement
concrete in proportion 1:1.5:3 (1 cement: 1.5 sand: 3 graded stone aggregate 10mm nominal size)
mixed with water proofing cement additive as approved by the Project Engineer and Executing
Agency. The additive shall be used in proportion recommended by the manufacturer.
The surface of masonry work shall be levelled and prepared before laying the cement concrete.
Edges of DPC shall be straight and even. The side shuttering shall consist of wooden forms and
shall be strong and properly fixed so that it does not get disturbed during compaction and mortar
does not leak through. The concrete mix shall be of workable consistency and shall be tamped
thoroughly to make a dense mass. When the side shuttering is removed the surface should be
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smooth without any honeycombing. The top surface shall be double chequered and cured by
pounding for atleast 7 days. The cement concrete shall be allowed to dry for atleast 24 hours after
curing and hot bitumen of grade 85/25 conforming to IS:702 at the rate of 1.7 kg/sq metre shall be
applied over the dried up surface of cement concrete after being properly cleaned with brushes and
finally with a cloth soaked in kerosene oil. The bitumen shall be applied uniformly so that no blank
spaces are left anywhere.
4.10 Dismantling and demolition
The term ‘Dismantling’ implies carefully removing without damage (up or down). This shall
consist of dismantling one or more part of the building as specified or shown on the drawings.
The term ‘Demolition’ implies breaking up. This shall consist of demolishing whole or part of work
including all relevant items as specified or shown on the drawings.
(a) All materials obtained from dismantling or demolition shall be the property of the Executing
Agency, unless otherwise specified and shall be kept in safe custody until handed over at
Executing Agency’s stores. Demolition shall be carried out in the shape and profile shown
on the drawings or as directed by the Project Engineer and Executing Agency.
(b) The dismantling or demolition shall always be planned before hand and shall be done in
reverse order of the one in which the structure was constructed. The scheme shall be got
approved from the Project Engineer and Executing Agency before starting the work.
4.10.2 Precautions
(a) Necessary propping, shoring and under pinning shall be provided for the safety of the
adjoining work or property before dismantling or demolition is taken up and the work shall
be carried out in such a way that no damage is caused to the adjoining work or property.
Wherever specified, temporary enclosures or partitions shall also be provided.
(b) All demolition work shall be carried out in conformance with the local safety regulations,
ensuring the safety of men and materials.
(c) Necessary precautions shall be taken to keep down the dust nuisance.
(d) All materials which are likely to be damaged during the operation shall be carefully removed
first.
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(e) Dismantling shall be done in a systematic manner. The dismantled articles shall be passed by
hand, where necessary, lowered to the ground (and not thrown) and then properly stacked as
(f) Where fixing is done by nails, screws, bolts, rivets, etc. dismantling shall be done by taking
out the fixing with proper tools and not be tearing or ripping off.
(g) All serviceable materials obtained shall be separated out and stacked properly as directed by
the Project Engineer and Executing Agency, upto a lead of 500m or handed over at Executing
Agency’s stores. All unserviceable materials, rubbish etc. shall be disposed off, as directed
4.11 Sampling testing and quality control
4.11.1 General
(a) The Concessionaire shall carry out all sampling and testing in accordance with the relevant
Indian Standards and/or International Standards and shall conduct such tests as are called for
by the Project Engineer and Executing Agency. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to
the directions of the Project Engineer and Executing Agency. Tests shall be done in the field
and at a laboratory approved by the Project Engineer and Executing Agency and the
Concessionaire shall submit to the Project Engineer and Executing Agency, the test results
in triplicate within three days after completion of a test. The Project Engineer and Executing
Agency may at his discretion, waive off some of the stipulations given below, for small and
unimportant operations.
(b) Material / work found unsuitable for acceptance shall be removed and replaced by the
Concessionaire. The works shall be redone as per specification requirements and to the
satisfaction of the Project Engineer and Executing Agency.
4.11.2 Quality assurance program
The Concessionaire shall submit and finalise a detailed field Quality Assurance Program according
to the requirements of the specification. This shall include setting up of a testing laboratory,
arrangement of testing apparatus / equipment, deployment of qualified / experienced manpower,
preparation of format for record, field quality plan etc. On finalised field quality plan, the Executing
Agency shall identify, customer hold points beyond which work shall not proceed without written
approval from the Project Engineer and Executing Agency.
Frequency of sampling and testing including the methods for conducting the tests are given in Table
- 2. The testing shall be done at site. The testing frequencies set forth are the desirable minimum
and the Project Engineer and Executing Agency shall have the full authority to carry out or all for
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tests as frequently as he may deem necessary to satisfy himself that the materials and works comply
with the appropriate specifications. Some of the type tests and performance tests which are not
included in the table shall be carried out at the manufacturer’s premises or at an independent
Government approved laboratory.
All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be
taken to keep the pretends properly aligned.
a) Deviation in vertically in total height of any wall of a building more than one storey in height
shall not exceed +/- 12.5 mm.
b) Deviation from vertical within a storey shall not exceed +/- 6mm per 3 m height.
c) Deviation from the position shown on the plan of any brickwork more than one storey in
height shall not exceed 12.5 mm.
d) Relative displacement between load bearing walls in adjacent storeys intended to be in a
vertical alignment shall not exceed 6 mm.
e) Deviation of bed joint from horizontal in any length upto 12 m shall not exceed 6 mm, and
in any length over 12m it shall not exceed 12.5mm total.
f) Deviation from the specified thickness of bed-joints, cross joints or pretends shall not exceed
+/- 3 mm.
Table 2: Frequency of sampling and testing

Type of
Sl. Nature of test / No. of samples Remarks/
material/ Method of test
No. characteristics of test and frequency acceptance norms
work
1 2 3 4 5 6
1. Burnt clay (a) Dimensions Clause No.5.2.1 Max. 8% deviation
bricks/Fly ash of IS:1077 for non-modular
bricks bricks. For modular
bricks as per Clause
no.5.2 of IS: 1077.
For face bricks as
per IS: 2691.
(b) Compressive IS:3495 (Part-1) As specified

strength
(c) Water absorption IS:3495 A set of 20 bricks Max. 20%.

(Part-2) (min.) for each lot However, 15% for
of 50,000 or part face bricks only.
224
Type of
work
1 2 3 4 5 6
thereof for all tests
(a to c)
(d) Efflorescence IS:3495 Moderate.

(Part-3) However for face
brick nil.
(e) War page IS:3495 For face brick 2.5

mm (max.)
II. Stone a) Type of stone by IS:1123 One set of stones of As specified.

petro graphic each type and from
examination each source.
b) Shape & size Physical Random As specified

measurement
c) Crushing IS:1121 One set of stones of As specified

strength (Part-I) each type and from
each source.
d) Water IS:1124 One set of stones of As specified

absorption each type and from
each source.
e) Durability IS:1126 One set of stones of As specified

each type and from
each source.
III. Sand a) General quality Visual One set of samples As specified

from each source of
material per 100
Cum. or part
thereof.
b) Deleterious IS:2386 (Parts-I One set of samples Clause 3.3 of

material & 2) from each source of IS:2116
material per 100
225
Type of
work
1 2 3 4 5 6
cum. or part
thereof.
c) Grading Sieve analysis as One set of samples Table-1 of IS:2116

per IS:2386 from each source of
(Part-I) material per 100
cum. or part
thereof.
IV. Cement a) Setting time IS:4031 One set of sample No separate testing
for each lot of is required in case
material received cement is tested for
preparation of
concrete mix
b) Compressive IS:4031 One set of sample No separate testing

strength for each lot of is required in case
material received cement is tested for
preparation of
concrete mix
V. Water a) Harmful IS:3025 Once a month for No separate testing

substances, each source is required in case
pH value water is tested for
concrete mix
b) Initial setting time IS:4031 Once a month for No separate testing

each source is required in case
water is tested for
concrete mix
c) Compressive IS:516 Once a month for No separate testing

strength each source is required in case
water is tested for
concrete mix
VI. Mortar a) Compressive Appendix-A of One sample Table-1 of IS:2250

strength IS:2250 (consisting of min 3
specimens)
226
Type of
work
1 2 3 4 5 6
b) Consistency Appendix-B of One sample for Clause 7.2 of

IS:2250 each type of mix IS:2250
c) Water Appendix-C of One sample for Clause 7.3 of

retentively IS:2250 each type of mix IS:2250
VII. Masonry a) Workmanship Visual & All work As per specification

construction Physical and Cl. No.11.0 of
measurement IS:2212 for
brickwork
b) Verticality Physical All work As per specification

and alignment measurement and Cl.No.6.3.4 of
IS:1905
227
Section - C5
Technical specification for plastering and allied works
228
Section - C5
Technical specification for plastering and allied works
Contents
5.1 Scope ......................................................................................................................................... 230

5.2 General requirements ................................................................................................................ 230
5.3 Codes and standards .................................................................................................................. 230
5.4 Materials ................................................................................................................................... 230
5.5 Mortar ....................................................................................................................................... 231
5.6 Plastering................................................................................................................................... 232
5.7 Pointing ..................................................................................................................................... 237
229
Section - C5: Technical specification for plastering and allied works
5.1 Scope
This part of the specification covers the requirements for plastering and allied works for all types
of masonry and concrete surfaces.
materials, etc. required for complete execution ofthe work in accordance with the drawings and as
described herein and/or as directed by the Project Engineer and Executing Agency.
The Concessionaire shall follow all safety requirements/rules during execution of the work.
I.S:1661 shall be followed as a general guidance for plastering work.
generally be available at Site with the Concessionaire.
In case of any conflict between this specification and those (IS Standards, Codes etc.) more
stringent shall prevail.
IS:383 - Coarse and fine aggregates from natural sources for concrete.
IS:712 - Building limes.
IS:1542 - Specification for sand for plaster
IS:1635 - Code of practice for field slaking of Building lime and preparation of
putty
IS:2250 - Code of practice for preparation and use of masonry mortar.
IS:2333 - Plaster-of-paris
IS:2402 - Code of practice for external rendered finishes
IS:2547 - Gypsum building plaster
IS:3150 - Hexagonal wire netting for general purpose
5.4 Materials
Materials namely, cement, sand, water, Coarse aggregate, shall be in accordance with Technical
Specifications for properties, storage and handling of common building materials.
230
Lime for preparation of putty or neeru for punning work shall be according to class B& C of IS:
712.
For rough cast plaster, coarse aggregate of size 6 to 12 mm shall be used in the finishing coat.
Coarse aggregate shall be as per IS: 383.
Gypsum, for use in plaster-of-paris punning work shall be according to IS:2333.
For lath plastering, galvanised hexagonal wire netting with wire 0.9mm dia and 12.5 mm mesh
conforming to IS:3150 shall be used.
5.5 Mortar
Unless otherwise specified cement & Fly ash (20% replacement ratio of cement with fly ash): -
sand mortar shall be used. Cement mortar shall be prepared by mixing cement & fly ash (20%
replacement ratio of cement with fly ash): and sand in specified proportions by volume. Sand shall
be measured on the basis of its dry volume using gauge boxes. Suitable allowance in quantity shall
be made to cater for the bulkage. Cement and fly ash shall preferably be measured by weight. For
the purpose of determining the corresponding volume, one cubic metre of cement shall be taken to
weigh 1440 Kg and one cubic metre of fly ash shall be taken to weigh 641 Kg (i.e. coal ash)
The mixing of mortars shall be done in mechanical mixer. However, depending on nature,
magnitude and location of the work, the Project Engineer and Executing Agency may relax the
condition of use of mechanical mixer and allow hand mixing.
Cement, fly ash and sand in the specified proportions shall be fed into the mixer and mixed dry
thoroughly in the mixer. Water shall then be added gradually and the wet mixing continued for at
least 3 minutes. Hand mixing shall be carried out on a clean, water tight platform. Only that
quantity of mortar, which can be used within 30 minutes of its mixing, shall generally be prepared
at a time. Care shall be taken, not to add more water than that which shall bring the mortar to the
consistency of a stiff paste. IS: 2250 and IS:1661 shall be referred for ascertaining the quantity of
water.
In case of cement mortar, the mortar that has stiffened because of evaporation of water from the
mortar may be retempered under special circumstances, with the approval of the Project Engineer
and Executing Agency, by adding water as frequently as needed to restore the requirements of
consistency but this retempering shall be permitted only upto one hour from the time of addition of
cement.
Cement mortar shall be used as soon as possible after mixing and before it begins to set, preferably
within half an hour from the time water is added to cement during mixing and in any case within
one hour thereof.
231
Sweep mortar shall not be used.
5.6 Plastering
5.6.1 Mix proportion and plaster thickness
The mix proportion and thickness of plaster for various surfaces shall be as specified or shown in
the drawings. Unless otherwise specified the following shall be adopted.
i. Ceiling plaster minimum 6mm thick cement mortar (1:4)

ii. Plaster on external / rough face of masonry 18mm thick, cement mortar* (1:6)
work or concrete surface
iii. Plaster on plain face of masonry work or 12mm thick, cement mortar*(1:6)
concrete surface.
*In case of special application like water proofing surface, base course of decorative finish etc.,
richer mix proportion not leaner than 1:4 shall be used.
5.6.2 Preparation of surface
The surface shall be cleaned of all dust, loose mortar droppings, traces of algae, efflorescence and
other foreign matter by water or by brushing. Smooth surfaces shall be roughened by wire
brushing, if it is not hard and by hecking when it is hard. In case of concrete surface, if a chemical
retarder has been applied to the framework, the surface shall be roughened by wire brushing and
all the resulting dust and loose particles cleaned off and care shall be taken that none of the retarders
is left on the surface.
Trimming of projections, wherever necessary shall be done to achieve an even surface. Ranking
of joints in case of brickwork where necessary shall be done. The masonry shall be allowed to dry
out for sufficient period before plastering.
For ceiling plaster, the concrete surface shall be pock marked with a pointed tool to ensure a proper
key for the plaster.
The wall shall be dampened evenly and not soaked before application of plaster. If the surface
becomes dry in spots, such areas shall be moistened again.
5.6.3 Sequence of plastering operations
For external plaster, the plastering operations shall be started from the top and carried downwards.
To ensure even thickness and a true surface, plaster about 15 x 15 cm shall be first applied
horizontally and vertically, at not more than 2m intervals over the entire surface to serve as gauges.
232
The surfaces of those gauged areas shall be truly in the plane of the finished plastered surface. For
internal plaster, the plastering operations may be started wherever the building frame and cladding
work are ready; the temporary supports of the ceiling resting on the wall have been removed.
The first undercoat shall then be applied to ceilings. After the ceiling plaster is completed and
scaffolding for the same removed, the first undercoat on walls shall then be applied.
After a suitable time interval as detailed under application of plaster, the second coat (finishing
coat) shall be applied, first to the ceiling and then to the walls.
Where corners and edges have to be rounded off, such rounding off shall be completed alongwith
the finishing coat to prevent any joint marks.
5.6.4 Application of plaster
 Wall / vertical surface plaster
Unless otherwise stated, the plastering above 12mm thick shall be carried out in two coats only.
i) The backing or first coat
The backing coat shall be 10 to 12 mm thick and carried to the full length of the all or to
natural breaking points like doors and windows. Before the rendering coat hardens, it shall
be roughened to provide mechanical key for the second coat.
Masonry walls on which plaster is to be applied directly, shall be properly set and cured with
the joints raked to a depth of at least 10 mm. The rendering coat shall be troweled hard and
tight, forcing it into surface depressions to obtain a permanent bond.
On smooth concrete walls, the surface shall be roughened and the rendering coat shall be
dashed on to ensure adequate bond. The dashing of the rendering coat shall be done using a
strong whipping motion at right angles to the face of the wall, or it may be applied with a
plaster machine or cement gun.
ii) Finishing coat
Before starting to apply the finishing coat, the surface of the backing coat shall be dampened
evenly. The final plastered surface shall be cured and kept continuously damp for minimum
7 days.
 Ceiling plaster
Stage scaffolding shall be provided for ceiling plaster. This shall be independent of the walls.
Projecting burrs of mortar formed due to gaps at the joints is shuttering shall be removed. The
surface shall be scrubbed clean with wire brushes. In addition, the concrete surfaces shall be pock
233
marked with a pointed tool at a spacing of not more than 50 mm centres, the pocks being made not
less than 3 mm deep, to ensure a proper key for the plaster. The mortar shall be washed off and all
surface cleaned of all oil, grease, etc. and well wetted before the plaster is applied.
Ceiling plaster shall not be commenced until the slab above has been furnished and centering has
been removed. The average thickness of plaster shall not be less than 6 mm. The minimum
thickness over any portion of the surface shall not be less than 5 mm.
The Surface shall be cured atleast twice a day for a minimum period of seven days.
 Grooves in plaster
Where specified in drawings, rectangular grooves 12 to 20 mm wide and 8 to 10 mm deep shall be

provided in external plaster by means of timber battens or metal strips, fixed on plaster when plaster
is still green. Battens or strips shall be carefully removed after initial set of plaster and broken edges
and corners made good. All grooves shall be uniform in width and depth and shall be truly plumb
and correctly aligned.
 Drip course
Drip course wherever indicated in the drawings shall be provided at the time of plastering to prevent
travelling of water drops from the projections. Unless otherwise, specified, projected strip form
drip course shall be provided.
 Metal lathing
The lathing shall be tightly stretched with the long way of the mesh across the supports before
nailing. This shall be secured with 25 mm galvanised steel staples or nails at 200 mm centres, if the
studding is of wood and with 0.90 mm iron tying wire, if the studding is of steel. Edges of lathing
shall be lapped not less than 25 mm at the sides and ends and wired together with galvanised wire
of diameter not less than 1.25 mm, every 100 mm between supports.
Before plastering, the surface of metal lathing shall be brushed over with thin cement slurry or
given a protective coat of bitumen oil paint.
234
Plastering to lathing
It shall be carried out in two coats. Mortars for the first coat shall be of stiff consistency and applied
as evenly as possible to give a uniform good cover to the lathing. It shall be allowed to dry until all
shrinkage movement has ceased before the second coat is applied. Too much pressure shall not be
used in applying plaster to lathing to guard against its deflection.
 Rough cast finish
The plaster base over which the rough cast finish is to be applied shall be done in general as per
Clause no. 5.6.2 under sub head "Application of Plaster".
It shall be ensured that the base surface which is to receive rough cast mixture is in plastic state.
Coarse aggregate of size 6 to 12 mm shall be used in the finishing coat. The grading and size shall
vary according to the texture required.
The rough cast mix shall be wetted and shall be dashed on the plaster base in plastic state by hand
scoop so that the mix gets well pitched into the plaster base. The mix shall again be dashed over
the vacant spaces, if any, so that the finished surface represents a homogeneous surface of sand
mixed with grovel. The surface shall be cured for a minimum period of 7 days.
5.6.5 Punning work
 Lime punning or Neeru finish
Materials
Lime putty: It shall be obtained by slaking lime with fresh water and sifting it. The slaking shall
be done in accordance with IS: 1635.
Neeru: It shall be obtained by mixing lime putty and sand in equal proportion and chopped jute @
4 Kg. per cu.m. of mortar. The mixture shall be properly ground to a fine paste between two stones.
235
Application of punning
Lime punning consists in finishing the interior with a thin coat (3 mm) of fat lime putty mixed with
an equal amount of sand. Before actual use, putty shall be matured for 2 to 3 days.
The mortar for punning shall be applied in 3 mm thick layer just after the undercoat has hardened.
It shall be finished to a smooth surface by means of a plaster's trowel.
The curing shall be started as soon as the punning has hardened but in any case not earlier than 24
hours after the punning has been completed. The punning shall be kept wet for a period of seven
days.
 Plaster of paris punning
The plaster of paris (gypsum Anhydrous) conforming to IS: 2547 shall be used for plaster of paris
punning. The plaster of paris shall be mixed with water to a workable consistency and shall be
applied on the plastered surface and finished to a smooth surface by steel float. The finished surface
shall be smooth and true to plane, slopes or curves as required. The nominal thickness of the
punning shall be 2 mm.
 Neat cement punning
The plastered surface over which neat cement punning is to be done, shall be uniformly treated
over its entire area with a paste of neat cement and rubbed smooth, so that the whole surface is
covered with neat cement coating. The quantity of cement applied shall be 1 kg. per sq. metre.
Smooth finishing shall be completed with a float immediately and in no case later than half an hour
of adding water to the cement.
5.6.6 Trueness of plastering system
The finished plastered surface shall not show any deviation more than 4 mm when checked with a
straight edge of 2 metre length placed against the surface.
236
5.6.7 Thickness of plaster
The thickness of the plaster shall be measured exclusive of the thickness of key i.e. grooves or open
joints in brickwork. The average thickness of plaster shall not be less than the specified thickness.
The minimum thickness over any portion of the surface shall not be less than the specified thickness
by more than 3 mm for plaster thickness above 12 mm and 1 mm for ceiling plaster. Extra thickness
required in dubbing behind rounding of the corners at junctions of wall or in plastering of masonry
cornices etc. shall be ignored.
5.6.8 Inspection and testing
a) The plastered surface shall be checked for following defects and the remedial measures for
the same shall be adopted as per IS: 1661.
i) Blistering
ii) Bound failure or loss of adhesion
iii) Cracking
iv) Crazing
v) Efflorescence
vi) Grinning
vii) Irregularity of surface texture
viii) Popping or blowing
ix) Recurrent surface dampness
x) Softness or chalkiness
b) Trueness of the plaster shall be checked as per Clause no. 5.6.6

c) Thickness of the plaster shall be checked as per Clause no. 5.6.7
5.7 Pointing
The materials, preparation of mortar etc. shall be same as specified for cement plaster works. The
mix proportion shall not be leaner than 1:3, unless otherwise specified. For all exposed brickwork
or stone masonry work, self supporting double scaffolding, having two sets of vertical supports
shall be provided so as to avoid openings in the wall.
5.7.1 Preparation of surface
The joints shall be raked out properly to such a depth that the minimum depth of the new mortar
measured from either the sunken surfaces of the finished pointing or from the edge of the brick
shall not be less than 10 mm. Dust and loose mortar shall be brushed out. Efflorescence, if any shall
be removed by brushing and scraping. The surface shall then be thoroughly washed with water,
cleaned and kept wet before commencement of pointing.
237
5.7.2 Application of mortar and finishing
The mortar shall be pressed into the raked out joints, with a pointing trowel, either flush, sunk or
raked, according to the type of pointing required. The mortar shall not spread over the corner, edges
or surface of the masonry. The pointing shall then be finished with the proper tool according to the
type of pointing required.
5.7.3 Type of pointing
 Ruled pointing
Unless otherwise specified ruled pointing shall be adopted for all exposed brick/block masonry
work However, for rubble masonry works, recessed pointing shall be adopted.
The mortar shall be pressed into the raked out joints and shall be finished off flush and then while
the mortar is still green, a groove of shape and size as shown in drawings shall be formed by running
a forming tool straight along the centre line of joints. This operation shall be continued till a smooth
and hard surface is obtained. The vertical joints shall also be finished in a similar way. The vertical
joints shall make true right angles at their junctions with the horizontal lines and shall not project
beyond the same. For recessed pointing in rubble masonry recess shall be provided along the centre
line of the joint profile.
 Flush pointing
The mortar shall be pressed into the joints and shall be finished off flush and level with the edges
of the brick, tiles or stones so as to give a smooth appearance. The edges shall be neatly trimmed
with a trowel and straight edge. Unless otherwise specified, flush pointing shall be adopted for
drains and brick on edge paving.
 Raised and cut pointing
Raised and cut pointing shall project from the wall facing with its edges cut parallel so as to have
a uniformly raised band about 6 mm raised and width 10 mm or more as directed. The superfluous
mortar shall be cut off from the edges of the lines and the surface of the masonry shall also be
cleaned off all mortar. Unless otherwise specified, raised and cut pointing shall be adopted for stone
masonry pointing, and shall be provided along the Centre line of the joint profile.
5.7.4 Curing
The pointing shall be kept wet for 7 days.
238
Sub section - C6
Technical specification for flooring and other allied works
239
Sub section - C6
Technical specification for flooring and other allied works
Contents
6.1 Scope ............................................................................................................................................. 241

6.2 Installation..................................................................................................................................... 242
240
Sub section - C6: Technical specification for flooring and other allied works
6.1 Scope
This specification cover the supplying, installation, finishing, curing, testing, protecting,
maintaining until handling over of various types of floor finishes and allied items of works as listed
below :
6.1.1 In situ finishes
Integral finishes to concrete base.
Terrazzo finish.
Metallic hardener like “Ironite” finish.
6.1.2 Tile finishes
Terrazzo tile
Glazed tile
Rubber based vinyl tiles
6.1.3 Base
The base to receive the finish is covered under other relevant specifications.
6.1.4 Sequence
The commencement, scheduling and sequence of the finishing works shall be planned in details
and must be specifically approved by the Project Engineer and Executing Agency, keeping in view
the activities of other agencies working in the area. However, the Concessionaire shall remain fully
responsible for all normal precautions and vigilance to prevent and damage whatsoever till handling
over to the Executing Agency.
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6.2 Installation
6.2.1 Special materials
Materials required for individual finishing items are specified under respective items. In general,
all such materials shall be in accordance with the relevant IS Codes (Latest edition) where
applicable. In all cases these materials shall be of the best indigenous quality unless specified
otherwise.
The materials for finishing items must be procured from well-reputed specialized manufactures and
on the basis of approval of samples by the Project Engineer and Executing Agency. The materials
shall be ordered, procured and stored well in advance to avoid possible delays to the construction
program.
6.2.2 Workmanship
Workers specially experienced in particular items of finishing work shall carry out the work. Where
such workers are not readily available, experienced supervisors recommended by the manufacturer
shall be engaged with the prior permission of the Project Engineer and Executing Agency. In
particular cases, Project Engineer and Executing Agency may desire the installation of finishing
items by the manufacturer. This arrangement shall be made by the Concessionaire.
6.2.3 Preparation of the base surface
The surface to be treated shall be thoroughly examined by the Concessionaire. Any rectification
necessary shall be brought to the notice of the Project Engineer and Executing Agency and his
approval shall be obtained regarding the method and extent of such rectification required. For all
types of flooring, skirting, dado and similar locations, the base to receive the finish shall be
adequately roughened by chipping, raking of joints and thoroughly cleaning of all dirts, grease etc.,
using water hard brushes and detergent as required, unless otherwise directed by the manufacturer
of any special finishing materials, or specifically indicated in this specification under the individual
item. To prevent absorption of water from any wet finishing treatment, the base shall be thoroughly
soaked with water and all excess water mopped up. However, the surface shall be dry where
adhesive are used for fixing the finishes. The actual finishing work shall not commence until the
Project Engineer and Executing Agency has approved the surface.
6.2.4 In-situ-finishes
 Integral finishing to concrete base
While the surface of the concrete laid in accordance with the specification for ‘’Cement Concrete’’
has been fully compacted and levelled but the concrete is still green, a thick slurry made with neat
cement shall be applied evenly and worked in with iron floats. When the slurry starts to set, it shall
be pressed with iron floats, to achieve a firm, compact and smooth surface without any trowel
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marks or undulations. The finish shall be as thin as possible by using 2.2 kg. of cement per sq.m.
of area. The surface shall not be subjected to any loads or abrasion for at least 21 days after laying.
When desired by the Project Engineer and Executing Agency, the surface while still ‘green’ shall
be intended by pressing strings. The markings shall be of even depth, in straight lines and the panels
shall be of uniform and symmetrical patterns.
 Terrazzo finish: In-situ
It shall consist of an underbed and a topping laid over an already laid and matured concrete base.
(a) Thickness
Unless otherwise specified, the total thickness of the finish shall be a minimum of 40 mm for
horizontal surfaces and 25 mm for vertical surfaces of which the topping shall be not less
than 10 mm. The topping shall be of uniform thickness but the underbed shall vary in
thickness as necessary to provide any slopes. The finished vertical surface shall project 6 mm
from the adjacent plaster or other finishes. The surface receiving the finish shall be cut back
as necessary to accommodate the specified thickness. All junctions between vertical and
horizontal surfaces shall be rounded neatly to a uniform radius of 25 mm.
(b) Mix
i) Underbed
The underbed for floors and similar horizontal surfaces shall consist of a mix of 1 part
cement, 1 part sand and 3 parts sand by volume. The sand shall be coarse. The stone
chips shall be 10 mm down well graded. Only sufficient water shall be added to provide
a mortar of workable consistency.
ii) Topping
The mix for the topping shall be composed of cement, colour pigment, marble dust and
marble chips. The proportions of the ingredients shall be such as to produce the terrazzo
of the colour, texture and pattern approved by the Project Engineer and Executing
Agency. The cement shall be white or grey or a mixture of the two in which the pigment
shall be added to achieve the desired colour. To 3 parts of these mixture, 1 part marble
powder by volume shall be added and thoroughly mixed dry to 1 part of this mix, 1 to
1.5 parts of marble chips by volume shall be added and thoroughly mixed dry again.
The pigment must be stable and non-fading. It must be very finely ground. The marble
powder shall l be from white marble and shall be finer than I.S. Sieve No. 30. The size
of marble chips may be between 1 mm to 20 mm but at least 5 mm smaller than the
topping thickness.
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Sufficient quantity to cover each visible area shall be prepared in on lot to ensure uniform
colour. Water to make it just workable shall be added to a batch immediately before it is
laid. The size of batch shall be such that it can be laid before it starts setting.
(c) Laying
The underbed shall be laid in panels. The panels shall not the more than 5 sq.m. in area of
which no side shall be more than 2.5 m long. For locations exposed to the sun, the maximum
ate of a panel shall be 2.0 sq.m. The panels shall be laid in alternate bays or chequered board
pattern. No panel shall be in contact with any other already laid until the later has contracted
to the full extent.
Dividing strips made of aluminium 40 mm wide and 2 mm thick (min) shall be used for
forming the panels. The strips shall exactly match the total depth of underbed plus topping.
After laying, the underbed shall be levelled, compacted and brought to proper grade with a
screed or float. The topping shall be laid after about 24 hours while the underbed is still
‘green’ but firm enough to receive the topping. Slurry of the mixture of cement and pigment
already made shall be spread evenly and brushed in just before laying and topping. The
topping shall be rolled for horizontal areas and thrown and pressed for vertical areas of extract
all superfluous cement and water and to achieve a compact dense mass fully bonded with the
underbed. The surface of the topping shall be trowelled over, pressed and brought to a smooth
dense surface showing at least 75% exposure of marble chips in an even pattern of
distribution over the area covered.
(d) Curing
The surface shall be left for curing for 12 to 18 hours and then cured by allowing water to
stand on the surface or by covering with wet sack for four days.
(e) Grinding and polishing
When the surface has sufficiently hardened it shall be watered and ground evenly with rapid
cutting coarse grade (No. 60) grit blocks till the marble chips are exposed and the surface is
smooth. Then the surface shall be thoroughly washed and cleaned. A grout already prepared
from a mixture of cement and pigment shall be applied to fill up all pinholes. This surface
shall be cured for 7 days by keeping it moist and then ground with fine grit block (No. 120).
It shall again be cleaned with water, the grout reapplied to fill up any more pinholes that
might have appeared and allowed be cured again for 5 days. Finally the surface shall be
ground a third time with very fine grid blocks (No. 320) to achieve a smooth surface free
from pinholes. Where a grinding machine cannot be used, hand grinding may be allowed
where the first rubbing shall be with carborundum stone of coarse grade No. 60, the second
rubbing with medium grade NO. 80 and the final rubbing and polishing with fine grade (No.
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120). The surface shall be cleaned with water, dried and covered with oil free clean saw dust
if directed by the Project Engineer and Executing Agency.
Just before handing over to the Executing Agency, the surface shall be dusted with oxalic
acid at the rate of 0.33 gm per sq.m., water sprinkled on to it and finished by buffing with
felt or hessian mops. The floor shall be cleaned with soft moist rag and dried, if desired by
the Project Engineer and Executing Agency, wax polish shall be applied. However, all excess
wax polish has to be wiped off and the surface left glossy but not slippery.
 Metallic hardener like ‘’ironite’’ finish
It shall consist of an underbed and a topping (incorporating iron particles) laid over an already laid
and matured concrete base.
(a) Thickness
Unless otherwise specified the total thickness of the finish shall be minimum of 52 mm for
horizontal surfaces of which topping shall not be less than 12 mm. The topping shall be of
uniform thickness, but the underbed shall vary in thickness to provide and slopes. Vertical
surfaces shall project 6 mm from adjacent plaster or other finishes. The surface receiving the
finish shall be cut back as necessary to accommodate the specified thickness.
(b) Material
The hardening compound shall be uniformly graded iron particles, free from non-ferrous
metal impurities, oil, grease, sand, soluble alkaline compounds or other injurious materials.
When desired by the Project Engineer and Executing Agency, actual samples shall be tested
for impurities.
(c) Mix
i) The underbed for floors and similar horizontal surfaces and for vertical surfaces shall be
prepared in accordance with Clause 6.2.4(b).
ii) The Proportion of the metallic hardener shall be as specified or as indicated by the
manufacturer. However, in absence of any such direction 1 part metallic hardener shall
be mixed dry with 4 parts cement, by weight. To this mixture 6 mm nominal size stone
chips shall be added in proportion of 1 part cement (mixed with hardener) to 2 parts of
stone chips by volume and uniformly mixed. A minimum quantity of water shall be
added to make it workable.
(d) Laying
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The concrete floor shall be laid in panels of 1m x 1m or as directed by the Project Engineer
and Executing Agency. Alternate panels shall be laid on the same day followed by the other
group of alternate panels the next day. The edges of the panels shall be supported either by
wooden strips or flat angle iron pieces fixed securely in position. The underbed shall be laid
to the required grade. The forms, if any, shall remain sufficiently projecting to take the
topping. The surface of the underbed shall be roughened by wire brush as soon as possible.
The junction of floor and walls, floors and dado or skirting shall be rounded off as directed.
The Wooden strips or flat iron pieces shall be removed from their places before the
succeeding alternate layers are laid.
The topping shall be laid while the concrete underbed is still ‘very green’ about 3 hours after
laying of the later. The topping shall be of uniform thickness and even dense surface without
trowel marks, pinholes, etc. The topping layer shall be pressed firmly, worked vigorously
and quickly to secure full bond with the underbed. Immediately after the initial setting starts,
the surface shall be finished smooth with a steel trowel.
The finished floor shall be cured for 7 days by keeping it wet.
6.2.5 Tile finishes
These shall included tiles, stone slabs and similar manufactured or natural items over an already,
laid and matured base of concrete or masonry by means of an underbed or an adhesive layer.
 Terrazzo tiles
This tiles finish shall consist of precast terrazzo tiles laid over an underbed.
(a) Thickness
The total thickness including the underbed shall be a minimum of 40 mm for floors and 30 mm for
walls unless otherwise specified.
The skirting, dado and similar vertical surfaces shall project 6 mm uniformly from the adjacent
plaster or other wall finishes. The surface receiving the finish shall be cut back as necessary to
accommodate the specified thickness.
(b) Tiles
The tiles shall be composed of an underbed and topping. The topping shall be of uniform thickness
not less than 10 mm. The total thickness including the topping shall be as specified but not less
than 20 mm. The underbed shall be composed of 1 part ordinary grey cement and 3 parts of stone
ships by weight, mixed with water.
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(c) Topping
The tiles for the topping shall be as specified under Clause 6.2.4 (b).
The tiles shall be cured at the shop for at least 14 days before delivery to the site. First grinding
shall be given to the tiles in the shop before delivery. Tiles shall be packed properly to prevent
damage during transit and storage. The tiles must be stored carefully to prevent staining by damp,
rust, oil, grease or other chemicals.
Tiles made in each batch shall be kept and used separately so that the colour of each area of the
floor shall be uniform. The manufacturer of the tiles shall also supply the grout mix containing
cement and pigment in the exact proportions as used in finishing the tiles. The containers for the
grout mix shall be suitably marked to ensure that they can be related to the particular type and batch
of tiles.
(d) Mix-underbed
The underbed for floors and similar horizontal surfaces shall be 1 part lime putty; 1 part surkhi; 2
parts coarse sand by weight mixed with sufficient water to form a stiff workable mass. For skirting
and dados and all vertical surfaces it shall be about 10 mm thick and composed of 1 part cement
and 3 parts sand by weight.
(e) Laying
The underbed mortar shall be evenly spread and brought to the appropriate grade and consolidated
to a smooth surface. The surface shall be roughened for better bond with the tiles. While the
underbed is still fairly moist but firm, cement shall be hand dusted over it or cement slurry applied.
The tiles shall immediately be placed in position and firmly pressed by wooden mallet on to the
underbed so that the tile surface achieves the desired level. The tiles shall be soaked in water for
about 10 minutes just before laying. The joints between tiles shall be as narrow as possible and not
more than 1.5 mm wide.
Special care shall be taken to check the level, the surface and the lines of the joints frequently so
that these are perfect.
When tiles are required to be cut to match the dimensions, they shall be sawn and edges rubbed
smooth. The location of cut tiles shall be planned in advance and approved by the Project Engineer
At the junction of horizontal surface with vertical surfaces the tiles on the former shall enter at least
12 mm under the later.
After fixing, the floor shall be kept moist sand allowed to mature undisturbed for 7 days. Heavy
traffic shall not be allowed.
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If desired, diving strips as specified under Clause 6.2.4 (c) may be used for dividing the work into
suitable panels.
(f) Grinding and polishing
The procedure shall be the same as specified in Clause 6.2.4 (e) but grinding shall not commence
until 14 days have elapsed after laying of tiles.
 Glazed tiles
This finish shall be composed of glazed, earthen, coarse tiles with an underbed laid over a concrete
or masonry base.
(a) Thickness
The total thickness shall be between 20 mm and 25 mm including the underbed.
The tile finish on vertical surface shall project 6 mm uniformly from the adjacent plaster or other
wall finishes. The surfaces receiving the finish shall be cut as necessity to accommodate the
specified thickness.
(b) Tiles glazed
The tiles shall be earthenware, covered with glazed, white or coloured, plain or with designs, of
this size approved by the Project Engineer and Executing Agency and 6 mm thick. The tolerance
shall be +/-1.5 mm for length and breadth and +/-0.5 mm for thickness. Specials like internal and
external angles, beads, covers, cornices, corner pieces etc., shall match. The top surface of the tiles
shall be glazed with an unfading stable gloss finish as desired by the Project Engineer and Executing
Agency. The tiles shall be flat and to shape. The colour shall be uniform and a fractured section
shall be fine grained in texture, dense and homogenous. The tiles shall be strong and free from
flaws like cracks, chips craze, spacks, crawlings etc., and other imperfections. The edges and the
underside of the tiles shall be completely free from glaze and the underside shall have ribs or
indentations for better anchorage with the fixing mortar.
The coloured tiles, when supplied, shall preferably come from one batch to avoid difference in
colour.
(c) Mix-underbed
This mix for the underbed shall consist of 1 part cement and 3 parts coarse sand by weight mixed
with sufficient water or any other mix if specified.
(d) Laying
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The under and tiling shall be laid as specified in Clause 6.2.4 (e).
(e) Finishing
The joints shall be cleaned and flush pointed with white cement and cured for 7 days by keeping it
wet. The surface shall be cleaned with soap or suitable detergent, washed fully and wiped with soft
cloth to prevent scratching immediately before handing over to the Executing Agency.
 PVC tiles and rolls as per IS-3462-1986
This covers PVC based vinyl Tiles and Rolls set with adhesive on to a concrete or masonry base.
An underbed may be required to secure a desirable surface and grade.
Tiles
Unless otherwise mentioned the tiles shall be squares of approved dimensions. The tolerance of
dimensions shall be +/-1.5 mm.
The tiles should be clandered laminated solid resilient unbreakable and flexible PVC Vinyl tiles in
sizes of 305 mm x 305 mm x 3 mm thick. This shall have properties of a high wear resistance and
resilience, designed to withstand high traffic and abrasion. All edges shall be cut true and square.
The colour shall be non-fading and uniform in appearance, insoluble in water and resistant to
alkalies cleaning agents and usual floor polishes.
Rubber based adhesive to be used for fixing tiles shall be Dunlop S-758 or Fevicol SR-998 or
equivalent or a recommended by the manufacture. The adhesive shall have a short drying time and
long life. Each container shall show the shelf life, date of manufacture and over age container shall
be immediately removed from the site.
Rolls
It should be clandered laminated solid resilient unbreakable and flexible PVC Vinyl Flooring of
size 1.5 mtrs. (Width) x 20 mtrs (Length) x 3 mm thick with inherent characteristics of wear
resistance, dimensional stability, elegance etc.
Each packet of tile or roll shall be legibly and indelibly marked with the manufacturer’s trade mark,
thickness, size batch number and date of manufacture.
Tiles shall be delivered securely packed and store in clean, dry, well ventilated places.
Joint welding
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This can be provided where ever the PVC Rolls are installed in order to avoid dust accumulation
leakage of water and prevention from wear and tear in joints. In this, a PVC cord is put into the
joint after making groves with machine and is welded with hot thermo welding machine.
(a) Mix Underbed
The underbed, where required to make up the specified thickness or to achieve the required grade
of the right type of surface shall be composed of 1 part cement, 2 parts sand and 4 parts stone chips
mixed with just sufficient water to make the mix workable.
(b) Laying
The tiles shall be stored in the room to be tied for atleast 24 hours to bring them to the same
temperature as the room. In air conditioning spaces, the air conditioned space, the tiles shall be
stored in the room to be tiled for at least 24 air conditioning shall be fully operational before the
tiling is laid.
The surface to receive this finish shall be firm, even textured but not too smooth, without
undulations and other deficiencies. If an underbed is laid, the same shall be cured for at least 7 days
by keeping it moist and then is shall be fully dried.
The surface shall be thoroughly cleaned. All loose dust particles shall be removed. Oil and grease,
if any shall be removed completely by the use of detergent.
The adhesive shall be applied uniformly to the fully dry surface in the desired thickness. The
adhesive shall also be applied to the backs and edges of the tiles and surface shall be allowed to
dry. The tiles shall then be placed neatly on the surface exactly to the approved pattern and set with
a suitable tool. If the edges tend to curl up, weights are to be applied to keep the edges down.
Special care shall be taken to avoid the formation of air pockets under the tiles. The joints shall be
very fine. Any adhesive squeezed out through the joints shall be removed immediately.
(c) Finishing
Any adhesive marks on the surface shall be removed by wiping with a soft cloth soaked in solvent.
The surface shall be cleaned with soft soap dried and then polished with approved type of polish
just before handling over to the Executing Agency.
6.2.6 Ground floor with earth subgrade
For ground floors having an earthen subgrade, the floor finish shall consist of the following:
 Compacted Earth
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i) 150 mm thick dry rubble soling on rammed earth. Rubble shall be hand packed as directed by
the Project Engineer and Executing Agency. This shall be laid closely in position on the
subgrade. All interstices between the stones shall be wedged in with smaller stones of suitable
size well driven to ensure tight packing and complete filling of the interstices. The filling shall
be carried out simultaneously with the placing in position of the rubble stone and shall not lag
behind. The small interstices shall be filled with hard clean sand well watered and rammed.
ii) 100 mm thick sand cushion.
iii) PVC sub-base 75 mm thick, 1:4:8 mix.
iv) Floor finish with underbed as specified elsewhere.
 Acceptance criteria
The finish shall be checked specially for:
(a) Level, slope, plumb as the case may be (The surface of the finish shall be smooth and within
+/-5 mm of the specified level or position. Local irregularities shall be within +/-3 mm when
measured against a 3 metre straight edge. Abrupt changes of alignment shall not exceed 2 mm).
(b) Pattern and symmetry
(c) Alignment of joints, dividing strips, etc.
(d) Color, texture
(e) Surface finish
(f) Thickness of joints
(g) Details of edges, junctions, etc.
(h) Performance
(i) Precautions specified for durability
 External wall treatment
Madrasi danna, vineratex, granotex, etc.
Madrasi Danna, Vineratex, or Granotex finishes, where indicated shall be applied with materials as
manufactured by the approved agencies. Stone finish, unless otherwise specifically mentioned,
shall be used.
Samples of materials shall be submitted to the Project Engineer and Executing Agency to approval
before the bulk purchase is made. The Concessionaire shall prepare test panels 1m x 1m in size and
obtain approval from the Project Engineer and Executing Agency before commencing actual
application of each type of finish.
The thickness of the finish shall not be less than 3 mm.
All surfaces to be finished shall be smooth and level and shall be thoroughly cleaned to remove any
grease, dirt or loose particles and shall be free from surface water.
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Extremely porous surfaces shall be pre-sealed with a thin coat of suitable primer. Previously painted
surfaces shall be prepared by scrapping off all loose paints, washing with a suitable detergent and
rinsing thoroughly with clean water. The finish shall be applied strictly in accordance with the
manufacturer’s instructions.
After application, the Concessionaire shall protect the surfaces against rain & sun until complete
hardness of the finish is achieved without any extra cost to the Executing Agency. This type of
work shall be carried out by specialized agencies only.
 I.S. codes
Some of the important applicable Indian Codes for this section are listed below. Latest editions of
these codes shall be follows:
IS : 777 - Glazed earthenware tiles

IS : 1237 - Cement concrete flooring tiles
IS : 1433 - Code of practice for laying and finishing of cement concrete flooring tiles.
IS : 2114 - Code of practice for laying in situ terrazzo floor and finishes.
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Sub section - C7
Technical specification for roof waterproofing insulation and allied works
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Sub section - C7
Technical specification for roof waterproofing insulation and allied works
Contents
7.1 Scope ............................................................................................................................................. 255

7.4 Materials ....................................................................................................................................... 256
7.5 Layers of treatments ...................................................................................................................... 256
7.6 Grading underbed.......................................................................................................................... 256
7.7 Insulation....................................................................................................................................... 257
7.8 Cellular concrete ........................................................................................................................... 258
7.9 Cement plaster .............................................................................................................................. 258
7.10 Waterproofing treatment ............................................................................................................... 258
7.11 Acceptance criteria........................................................................................................................ 263
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Sub section - C7: Technical specification for roof waterproofing insulation and allied works
7.1 Scope
This specification covers furnishing, installing, finishing, curing, testing, protecting, maintaining
till handing over of roof waterproofing, thermal insulation and allied works for buildings.
materials etc., required for complete execution of the work in accordance with the drawings and as
described herein and / or as directed by the Project Engineer and Executing Agency.
The Concessionaire shall follow all safety requirements / rules during execution of the work.
The Concessionaire should have adequate experience in execution of such works. Alternatively,
he should engage specialized agency for executing the work after obtaining approval from the
generally be available at site, with the Concessionaire.
In case of any conflict between this specification and those (IS Standards, Codes etc.) more
stringent shall prevail.
Some of the applicable Indian Standards, Codes, etc are referred to here below:
IS : 702 - Specification for industrial bitumen

IS : 1203 - Methods of testing tar and bitumen
IS : 1237 - Specification for cement concrete flooring tiles
IS : 1322 - Specification for bitumen felts for water proofing and damp
proofing
IS : 1346 - Code of practice for water proofing of roofs with bitumen
felts
IS : 1580 - Specification for bituminous compound for waterproofing
and caulking purposes
IS : 3067 - Code of practice for general design details and preparatory
work for damp- proofing and water proofing of buildings
IS : 3384 - Specification for bitumen primer for use in water proofing
and damp- proofing
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IS : 5916 - Safety code for construction involving use of hot
bituminous materials
IS : 6598 - Specification for cellular concrete for thermal insulation
7.4 Materials
Bitumen felt for waterproofing treatment shall be Hessian base self - finished felts of specified type
and grade conforming to IS: 1322
Bitumen primer shall conform to IS: 3384
The bonding material between the felt and the roof surface and between the successive felts shall
be industrial blown type bitumen of specified grade (s) conforming to IS: 702
Cellular concrete (foam concrete) for insulation of roof shall be cast - in - situ of specified type
conforming to IS: 6598
Materials for cement mortar under bedding and cement sand plaster over cellular concrete shall be
as specified for plastering and allied works
Materials for cement concrete under bedding work shall be as specified for concrete and allied
works
7.5 Layers of treatments
Various layers of treatment required for roof waterproofing and insulation work shall be as given
below
However different layers which are to be actually provided for various areas shall be as shown in
the drawings and directed by the Project Engineer and Executing Agency.
a) Grading underbed
b) Insulation (Cellular concrete)
c) Cement plaster and
d) Waterproofing treatment
7.6 Grading underbed
The underbed shall be laid to provide an ultimate run-off gradient not less than 1 in 100 or as
specified in the drawing and as directed by the Project Engineer and Executing Agency. Upto an
average thickness of 25mm the underbed shall usually be composed of cement and sand plaster.
For higher thickness the underbed shall be made with cement concrete. However actual thickness
and other details shall be as per approved drawings well defined cracks other than hair cracks in
the roof structure shall be cut to 'V' section, cleaned and filled up flush with cement - sand slurry
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or with cold applied bituminous caulking compound conforming to IS: 1580. The roof surface shall
be cured prior to the application of underbed.
The surface of roof and that part of the parapet, gutters, drain mouths etc., over which the underbed
is to be applied shall be roughened and thoroughly cleaned of all foreign matter namely fungus,
moss and dust, with wire brushing and dusting. Oil patches if any shall be removed with detergent.
The surface shall be soaked with water and all excess water removed just before laying of the
underbed.
The underbed shall not be laid under direct sunlight and shall be kept in shade immediately after
laying, so as to avoid quick loss of water from the mix and separation from the roof surface. The
underbed shall be cured under water twice a day for at least 7 days.
The underbed shall be finished to receive the waterproofing treatment directly or insulation as the
case may be.
7.6.1 Cement mortar underbed
The grading plaster shall have an average thickness of 25mm. It shall consist of cement and sand
in the ration of 1:4 by volume. The sand and cement shall be thoroughly mixed dry before water is
added. Each batch of mix shall be consumed before the initial set starts.
The plaster shall be laid to proper grade in continuous operation and fully compacted. The surface
shall be even and reasonably smooth. For detailed specification of plastering work Section -C5
shall be followed.
7.6.2 Cement concrete underbed
The concrete shall be used where the underbed is more than 25mm (average) thick. It shall consist
of cement concrete 1:2:4 mix by volume (1 cement: 2 sand: 4 graded stone aggregate. 12.5 mm
down stone nominal size). The aggregate shall be thoroughly mixed dry and minimum quantity of
water shall be added to make the mix workable.
The mix shall be laid to proper grade in continuous operation and full consolidated. The surface
shall be even and smooth. For detailed specification of concrete work Section C3 shall be followed.
7.7 Insulation
Insulation shall consist of cast-in-situ cellular concrete conforming to IS: 6598.
The cellular concrete of thickness 40 mm (minimum) shall be laid over the grading underbed over
precast/cast-in-situ RCC roofs. The cellular concrete shall be laid directly over the surface of the
roof without separate under bedding and the slope be provided by cellular concrete, wherever
shown in the drawings and / or as directed by the Project Engineer and Executing Agency.
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7.8 Cellular concrete
It shall consist of cast - in - situ light weight concrete formed by producing gas or air bubbles
in cement slurry or a cement - sand slurry. The cement slurry or cement - sand slurry. The
material shall be cured under natural conditions i.e., under ambient pressure and temperature by
water. The material shall have a density of 320 kg/cu.m. crushing strength of minimum 2.5 kg/sq.m.
value of thermal conductivity of maximum 0.7 mW/cm deg at 50 degree Centigrade mean
temperature i.e., Type A.
Before start of the laying of the cellular concrete, samples shall be prepared at site got tested. The
approval of the Project Engineer and Executing Agency shall necessarily be obtained.
Cellular concrete laid shall be sufficiently strong to take the usual workloads and standard loads
expected on the roof. Any damaged portion shall be removed and replaced forthwith.
While laying the cellular concrete, samples from each batch of the mix shall be kept for test, if so
desired by the Project Engineer and Executing Agency.
The approval of the Project Engineer and Executing Agency shall be taken before laying the layer
of cement plaster over the cellular concrete.
7.9 Cement plaster
After laying the insulation (cellular concrete), the surface shall be regarded with cement plaster and
made ready as required to receive the waterproofing treatment.
The top surface of insulation shall be finished, with 12mm (minimum) thick, or as specified in the
item 1:4 cement - sand plaster by volume to get an even and smooth surface. The sand and cement
shall be thoroughly mixed dry before water is added to it. Each batch of the mix shall be consumed
before the initial set starts. It shall be cured twice a day for at least seven days before laying the
waterproofing course. For detailed specification of plastering work MODULE / shall be followed.
7.10 Waterproofing treatment
7.11.1 Preparatory work
IS: 3067 shall be followed as a general guidance for preparatory work.
Waterproofing treatment shall be carried out into the drain pipe or outlets by at least 100mm. The
waterproofing treatment laid on the surface shall overlap the upper age of the waterproofing
treatment in the drain outlets by at least 100 mm.
Drain outlets shall be suitably placed with respect to the roof gradient to ensure rapid drainage and
prevent local accumulation of water on the roof surface. Masonry drain mouths shall be widened
two and a half times the diameter of the drain and rounded with cement mortar.
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Forecast iron outlets a groove shall be cut all round to tuck the treatment.
When a pipe passes through a roof on which waterproofing treatment is to be laid, a cement concrete
angle - fillet shall be built round it and the waterproofing treatment taken over the fillet.
In case of parapet walls above 450mm in height, for tucking in the waterproofing treatment a
horizontal groove at a minimum height of 150mm above roof level shall be left in the vertical face
at the time of construction. This groove shall be 75mm wide and 65mm deep. The horizontal face
of the groove shall be shaped with cement mortar 1:4.
In case of low parapets, where the height does not exceed 450mm, no groove shall be provided and
the waterproofing treatment shall be carried right over the top.
In the case of existing RCC and stone walls, cutting the chase for tucking in the waterproofing
treatment is not recommended.
At the junction between the roof and the vertical face of the parapet wall, a fillet 75mm (min) in
radius shall be constructed.
At the drain mouths, the fillet shall be suitably cut back and rounded off for easy application of the
waterproofing treatment and easy flow of water.
Outlets at every low dividing wall, about less than 300mm in height, shall be cut open to full depth
and the bottom and sides shall be rendered smooth and corners rounded off for easy application of
waterproofing treatment.
The surface to be coated with bitumen primer shall be cleaned with wire brushes and cotton or
gunny cloth. All loose materials shall be removed and surface shall be further cleaned with a piece
of cloth lightly soaked in kerosene oil. The surface shall be painted when it is completely dry.
Bitumen primer (priming coat) shall be used prior to the application of the first mopping coat of
hot molten bitumen to promote the bonding of the bitumen with the surface. The bitumen primer
shall be liquid bitumen of low viscosity which shall penetrate into the prepared surface upon
application. It shall be free from water and it shall conform to IS: 3384. It shall preferably be made
from the same grade of bitumen as used in bonding.
The bitumen primer shall be brushed over the surfaces and allowed to dry. Generally, a quantity of
0.27 litres per sq.m. (Minimum) is recommended.
The bonding material between the felt and the roof surface and between the successive felts shall
be industrial blown type bitumen of Grade 85/25 or 90/15 conforming to IS: 702 to withstand local
conditions of prevailing temperature and gradient of roof surface. For top dressing bitumen used
shall be industrial blown type of allowable penetration not more than 40 when tested in accordance
with IS : 1203.
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For vertical surface upto 1 meter height blown type bitumen of grade 85/25 or 90/15 and above 1
metre height grade 115/25 shall be used.
Bitumen tar felt of type 3, grade 1 conforming to IS: 1322 shall be used for roof waterproofing and
the treatment shall be done as per IS: 1346.
The Concessionaire shall state the source from where he proposes to procure the materials. The
Concessionaire shall satisfy the Project Engineer and Executing Agency that the bonding material
proposed to be used is suitable for the particular job. Test certificates for the bonding material shall
also be submitted and samples, if desired by the Project Engineer and Executing Agency shall be
provided for confirmatory tests. Sample of the self - finished felt shall be submitted in advance to
the Project Engineer and Executing Agency along with test certificates for his review. Samples of
stone grit shall be submitted if instructed by the Project Engineer and Executing Agency. The stone
grit shall be 6mm and down size and shall be devoid of fine sand. Test certificates shall be furnished
with each batch of bulk supply for Project Engineer and Executing Agency 's approval.
7.11.2 Course of treatment
The waterproofing treatment shall consist of a seven course treatment. Each layer of bonding
materials, self - finished bitumen felt or stone grit is counted as one course.
Brief description of various courses of treatment shall be as follows:

Heavy treatment - seven courses for severe conditions:
1 Primer conforming to IS : 3384 at the rate of 0.27 litre / sq.m minimum

2 Hot applied bitumen at the rate of 1.2 kg/sq.m minimum
3 Hessian - base self finished felt, Type - 3, Grade 1
4 Hot applied bitumen at the rate of 1.2 kg/sq.m minimum
5 Hessian - base self finished felt, Type 3, Grade 1
6 Hot applied bitumen at the rate of 1.2 kg/sq.m, minimum and
7 Grit, devoid of fine sand, at the rate of 0.006 cu.m/sq.m
7.11.3 Surface finish
When the roof surface is subjected to foot traffic or used as a working area, a cement mortar (1:4)
shall be applied over the top most layer of roofing treatment. Over this, a layer of cement concrete
flooring tiles conforming to IS: 1237 shall be provided in place of stone grit and cement painted.
The tiles shall be laid as per IS: 1443. Alternatively, a screening of proportion of 1:4 of cement
and sand 45mm thick can be laid over the roof treatment wherever shown in the drawing and
marked off into square of 600mm made with expansion joints provided at a distance of 3 metre
which shall be properly caulked with bituminous sealing compound conforming to grade A of IS:
1834.
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Waterproofing treatment shall be carefully carried out from the time the surface is prepared to
receive the felt to the finishing of the treated surface. Special attention and strict supervision shall
be necessarily paid to overlapping of joints in felts, treatment around drainage openings in the roof
and treatment of the parapet walls. The sticking of the felt to the roof by means of hot bitumen also
requires skill. In order to achieve this, the waterproofing treatment shall be laid by a specialist firm
with long experience in this particular line. The surface to receive the waterproofing treatment must
be cleaned of all foreign matter, namely fungus, moss, dust etc by wire brushing and dusting and
dried satisfactorily and the approval of the Project Engineer and Executing Agency taken before
starting the work. If any existing top course shall be completely removed and all damaged felts or
other defects repaired. The Project Engineer and Executing Agency may instruct the
Concessionaire to lay part of the stipulated course at the first instant to be followed later on with
the balance courses. This interim finish shall be done with a course of hot applied bitumen. While
doing the balance, hot bitumen shall be applied again to start with after repair of all damages to the
already laid courses.
The bitumen bonding material of specified grade shall be prepared by heating to the correct working
temperature specified by the manufacturer and maintained at that temperature. It shall then be
conveyed to the point of work in a bucket or pouring can, poured and spread on the surface in a
uniform continuous coating at the specified rate. For very large roofs, use of a spray machine is
recommended to secure even spreading. The surface shall be carefully examined for gaps or pin
holes, which on location shall be carefully filled up with the bitumen. Bitumen shall be applied
carefully so that the exposed faces are not disfigured by splashing or spattering the bitumen all
over.
The coat of bitumen shall be continued at least 15cm along the vertical surfaces joining the roof.
In case of parapet walls, it shall be continued upto the drip course.
The self finished felt shall be cut to the required lengths, brushed clean of dusting material and laid
out flat on the roof and allowed to soften, to eliminate curls and subsequent stretching. The felt
shall normally be laid in lengths at right angles to the direction of run-off gradient, commencing at
the lowest level and working upto the crest so that the over-laps of the adjacent layers of felt shall
offer minimum obstruction to the flow off of water. The felt shall not be laid in single piece of very
long lengths as they are likely to shrink. Six to eight metres are suitable lengths. Each length of felt
prepared for laying as described above shall be laid in position and rolled up for a distance of half
its length. The hot bonding material heated to correct working temperature as specified by the
manufacturer, shall be poured on to the roof across the full width of the rolled felt as the latter is
steadily unrolled and pressed down. The excess bonding material which squeezes out at the ends
shall be removed as the laying proceeds. The pouring shall be so regulated that the correct weight
of bonding, material per unit area is spread uniformly over. When the first half of the strip of felt
has been bonded to the roof, the other half shall be rolled up and then unrolled on to the hot bonding
material in the same way. Subsequently strips shall also be laid in the same manner. Each strip shall
overlap the preceeding one by at least 75mm at the sides of strip of felt and at least 100mm at the
ends. All overlaps shall be firmly bonded with hot bitumen. Streaks and trailings of bitumen near
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edges of laps shall be levelled by heating the overlaps with a blow lamp and leveling down
unevenness.
In a seven course treatment the fourth and sixth layers of bonding material and the fifth layer of
self-finished felt shall be laid in the manner already described, taking care that the joints are
staggered with those in the layer beneath it i.e., third layer. The sixth layer shall be carried out after
the flashing is done.
Immediately after application of top layer of bitumen stone grit shall be evenly spread and levelled
over the surface when the bitumen is still hot.
After completion, the surface shall be cleaned taking care that loose gravels, felt cuttings, etc. do
not find their way into rain down corners.
The surface level shall be such as to allow quick draining of rains without leaving any pool
anywhere. The finishing course shall be fully secured and shall have an even density. There shall
not be any bubble formation or crushed or squeezed insulation or underbed.
For heat reflecting surface or for aesthetic reasons bitumen based aluminium paints or coloured
bituminous emulsions may be used as directed by the Project Engineer and Executing Agency.
7.11.4 Flashing
Felt shall be laid as flashings in widths wherever junctions of vertical and horizontal structures (i.e.,
roof surface and parapet wall or any other vertical structure) occur with minimum overlap of
100mm. The lower layer of flashing felt in seven course treatment shall overlap the roof
waterproofing by not less than 200mm while upper layer shall overlap the roofing felt by 100mm.
On the vertical and sloping faces last course of flashing should not be of stone grit or pea-sized
gravel, but it shall be replaced by providing two coats of bituminous paint at the minimum rate of
0.1 litres/sq.m per coat or a single coat of bituminous emulsion at the rate of 0.5 litre/sq.m may be
applied.
The lower edge of flashing shall overlap the felt laid on flat portion of the roof and the upper edge
of the flashing shall be tucked into the horizontal groove 75mm thick wide 65mm deep, provided
at a minimum height of 150mm from top of the roof surface. The flashing treatment shall be firmly
held in place in the grooves with wooden wedges at intervals and the grooves shall be filled with
cement mortar 1:4 (1 cement: 4 coarse sand) or cement concrete 1:2:4 (1 cement: 2 coarse sand: 4
graded stone aggregate 6 mm nominal size) and surface of flashing.
After the top flashing felt layer has been laid, the penultimate layer of bonding material shall be
applied over the roofing felt and horizontal overlaps and vertical and sloping surfaces of flashing
at the specified rate. Then grit or gravel shall be spread uniformly over the hot bonding material on
the horizontal surface and pressed into it with a wooden roller.
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Where waterproofing treatment is required to be isolated from the roof structure, bitumen saturated
felt shall be spread over the roof surface and tucked into the flashing grooves. To keep these felts
free from the structure, no bonding material shall be used below these felts.
7.11.5 Fillets
All along the junction of the roof surfaces and vertical walls cement mortar (1:4) fillet shall be
provided. The fillets shall be 150mm x 150mm in size unless otherwise shown on drawing or
instructed by the Project Engineer and Executing Agency. The shape of the fillet shall slightly be
concave.
Cast-in-situ cement concrete (1:2:4 with 12.5mm down aggregate) or cement mortar 1:4 shall be
used to provide fillet.
7.11.6 Expansion joints
Expansion joints shall be designed to suit the requirements of each roof. Expansion joint coverings
shall be of bitumen felt. In this case, a minimum of two layers of bitumen felt, Type 2, Grade 2 as
specified in IS: 1322 shall be used with top dressing gravel or other suitable finish.
7.11 Acceptance criteria
The surface level shall be such as to allow quick draining of rains without leaving any pool
anywhere. The finishing course shall be fully secured and shall have an even density. There shall
not be any bubble formation or crushed or squeezed insulation or underbed.
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Sub section - C8
Technical specification for painting, white washing, etc.
264
Sub section - C8
Technical specification for painting, white washing, etc.
Contents
8.1 Scope ............................................................................................................................................. 266

8.2 Materials ....................................................................................................................................... 266
8.3 Storage .......................................................................................................................................... 268
8.4 Preparation of surface ................................................................................................................... 268
8.5 Application.................................................................................................................................... 269
8.6 Painting of iron work .................................................................................................................... 271
8.7 Protection ...................................................................................................................................... 272
8.8 Cleaning up ................................................................................................................................... 272
8.10 Painting of structural steel / miscellaneous steel........................................................................... 272
265
Sub section - C8: Technical specification for painting, white washing, etc.
8.1 Scope
This specification covers painting, white washing, etc. of both interior and exterior surfaces of
masonry, concrete, plastering, plaster of Paris, rain water down comers, floor and roof drains, waste
and service water pipes and other items, as directed by the Project Engineer and Executing Agency.
If the surface to be finished cannot be put in a suitable condition for painting by customary
preparatory method, the Concessionaire shall notify the Project Engineer and Executing Agency in
writing and assume responsibility for any rectification and unsatisfactory finishing that might
result.
Before commencing painting, the Concessionaire shall obtain the approval of the Project Engineer
and Executing Agency in writing regarding the scheduling of work to minimise damage,
disfiguration or staining by other trades. He shall also undertake necessary precautions to prevent
damage, disfiguration or staining of other trades or other installations.
8.2 Materials
Materials shall be the highest grade products of well known approved manufacturers and shall be
delivered to the site in original sealed containers, bearing brand name, manufacturer’s name and
colour shade, with labels intact and seals unbroken. All materials shall be subject to inspection and
approval by the Project Engineer and Executing Agency. It is desired that materials of one
manufacturer only shall be used as far as possible and paint of one shade be obtained from the same
manufacturing batch. All paints shall be subjected to analysis from random samples taken at site
from the painter’s bucket, if so desired by the Project Engineer and Executing Agency.
All primer coats shall be compatible to the material of the surface to be finished as well as to the
finishing coats to be applied.
All unspecified materials shall be of the highest quality available and shall conform to the latest IS
standards. All such materials shall be made by reputable recognised manufacturers and shall be
approved by the Project Engineer and Executing Agency.
All colours shall be as per the painting schedule and tinting and matching shall be done to the
satisfaction of the Project Engineer and Executing Agency. In such cases, where samples are
required, they shall be executed in advance with the specified materials for the approval of the
8.2.1 Synthetic enamel paint
Shall be made from synthetic resins and drying oil with rutile titanium dioxide and other selected
pigments to give a smooth, hard, durable and glossy finish to all exterior and interior surfaces.
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White and pastel shades shall resist yellowing and darkening with ageing, The paint shall conform
to IS:2932 and IS:2933.
8.2.2 Waterproof cement paint
Shall be made from best quality white cement and lime resistant colours with accelerators,
waterproofing agents and fungicides. The paint shall conform to IS:5410.
8.2.3 Dry distemper
Dry distemper of required colour conforming to IS: 427 of approved brand and manufacturer shall
be used. The primer where used shall be cement primer or distemper primer. These shall be of same
manufacturer as that of distemper.
8.2.4 White washing
White washing shall be done from pure shell lime or fat lime, or a mixture of both as instructed by
the Project Engineer and Executing Agency and shall conform to IS:712 (latest edition) Samples
of lime shall be submitted to the Project Engineer and Executing Agency for approval and lime as
per the approved samples shall be brought to site in an unslaked condition. After slaking, it shall
be allowed to remain in a tank of water for two days and then stirred up with a pole, until it attains
the consistency of thin cream. 100 grams of gum to 6 litres of white wash water and a little quantity
of indigo or synthetic ultramarine blue shall be added to the lime.
8.2.5 Colour wash
Shall be done with mineral colours not affected by lime added to white wash. No colour wash shall
be done until a sample of the colour wash to the required tint or shade has been approved by the
Project Engineer and Executing Agency. The colour shall be of even tint or shade over the whole
surface. If it is blotchy or otherwise badly applied, it shall be redone by the Concessionaire at his
own cost.
8.2.6 Acrylic emulsion paint
Shall be water based acrylic copolymer emulsion with rutile titanium dioxide and other selected
pigment and fungicide. It shall exhibit excellent adhesion to plaster and cement surface and shall
resist deterioration by alkali salts. The paint film shall allow the moisture in wall to escape without
pelling or blistering the paint. After it is dried, the paint should be able to withstand washing with
mild soap and water without any deterioration in colour or without showing flaking, blistering or
peeling.
8.2.7 Oil bound distemper
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Oil bound distemper (IS:428-1969) of approved brand and manufacture shall be used. The primer
where used be cement primer or distemper primer. These shall be of same manufacturer as that of
distemper. The distemper shall be diluted with prescribed thinner in a manner recommended by the
manufacturer. Only sufficient quality of distemper required for a day’s work shall be prepared.
8.2.8 Chemical resistant paint
Chemical resistant paint as per IS:157 of approved brand and manufacture shall be used. Primer
coat to be used shall be as per manufacturer’s specifications.
8.2.9 Fire resistant paint
Fire resisting paint (silicate type) shall be as per IS:162 and of approved brand and manufacture.
Primer to be used shall be as per manufacturer’s specifications.
8.2.10 Oil resistant paint
Oil resistant paint shall be as per IS:161 and of approved brand and manufacturer. Primer coat shall
be as per manufacturer’s specifications.
8.3 Storage
The Concessionaire shall arrange for safe and proper storage of all materials and tools. Paints shall
be kept covered at all times and mixing shall be done in suitable containers. All necessary
precautions shall be taken by the Concessionaire to prevent fire.
8.4 Preparation of surface
Before starting the work, the Concessionaire shall obtain the approval of the Project Engineer and
Executing Agency regarding the soundness and readiness of the surface to be painted on.
8.4.1 Masonry, concrete and plastered surface
The surface shall be free from all oil, grease, efflorescence, mildew, loose paint or other foreign
and loose materials. Masonry cracks shall be cleaned out and patch filled with mortar similar to the
original surface and uniformly textured. Where this type of resurfacing may lead to the finishing
paint being different in shade from the original surfaces, the resurfaced area shall be treated with a
minimum of one coat of cement primer and should be continued to the surrounding area for a
distance of atleast 100mm.
Surfaces with mildew or efflorescence shall be treated as below:
a. Mildew
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All mildewed surfaces shall be treated with an approved fungicide such as ammoniacal wash
consisting of 7 gm. of copper carbonate dissolved in 80 ml liquor and diluted to 1 liter with water
or 2.5 percent magnesium silica fluoride solution and allowed to dry thoroughly before paint is
applied.
b. Efflorescence:
All efflorescence shall be removed by scrubbing the affected surface with a solution of mariatic
acid and in water (1:6 to 1:8) and then washed fully with clear water and allowed to dry thoroughly.
8.4.2 Metal
All metal surfaces shall be absolutely clean, dry and free from wax, grease and soap films. All steel
and iron surfaces in addition shall be free from rust. All galvanised iron surfaces shall be pretreated
with a compatible primer according to the manufacturer’s direction. Any abrasion in shop coat shall
be touched up with the same quality of paint as the original coat.
8.5 Application
8.5.1 General
The method of application shall be as recommended by the manufacturer. In case of selection of a

special shade and colour (not available in standard shades) the Concessionaire shall prepare test
panels in different shades of minimum size 1 metre square as instructed by the Project Engineer
and Executing Agency and obtain his approval prior to applications of the finishing paints.
Proper tools and implements shall be used. Scaffolding if used shall be independent of the surface
to be painted to avoid shade differences of the freshly repaired anchor holes. Painting shall be done
by skilled labour in a workman like manner. All materials shall be evenly applied, so as to be free
of sags, runs, crawls or other defects. All coats shall be of proper consistency. In case of application
by brush, no brush marks shall be visible. The brushes shall be clean and in good condition before
application of the paint.
All priming undercoats for painting shall be applied by brush only. Roller and spray equipment,
etc., shall not be used.
No work shall be done under conditions that are unsuitable for the production of good results. No
painting shall be done when plastering is in progress or is drying. Paint which seals the surfaces to
moisture shall be applied only after the moisture on and below the surface has dried out.
All coats shall be thoroughly dry before being sand papered or before the succeeding coat is applied.
Coats of painting as specified are intended to cover surfaces perfectly. In case the surface is not
269
covered properly by applying the specified number of coats, further coats shall be applied by the
Concessionaire when so directed by the Project Engineer and Executing Agency.
All primers and under coats shall be tinted to approximate the colour of the finishing coats. Finished
coats shall be of exact colour and shade as approved samples and all finish shall be uniform in
colour and texture. All parts of mouldings and ornaments shall be left clean and true to finish.
8.5.2 Synthetic enamel paint
Shall be applied on properly primed surface. Subsequent coat shall not be applied till the previous
coat is dry. The previous coat shall be lightly sand papered for better adhesion of subsequent coats.
8.5.3 Waterproof cement paint
Surface to be coated with cement paint shall be washed and brushed down. As soon as the moisture
has disappeared, the surface shall be given one coat of paint. Care shall be taken so that the paint
does not dry out too rapidly. After 4 to 6 hours, the water shall be sprinkled over the surface to
assist curing and prevent cracking. After the first, coat has dried (24 to 48 hours), the second coat
shall be applied.
In a similar manner the finished surface shall be kept moist by occasional sprinkling with water for
seven days after painting.
8.5.4 Dry distemper
New plastered surface shall be allowed to dry for atleast two months. New lime or lime plastered
surface shall be washed with a solution of 1 part of vinegar to 12 parts water or 1:50 sulphuric acid
solution and left for 24 hours after which the wall shall be thoroughly washed with clean water. For
cement plastered surface, the surface shall be washed with a solution of 100 gms of zinc sulphate
to 1 litre of water and then allowed to dry.
Dry distempering shall be done as per manufacturer’s instruction. In applying the distempers, the
brush should first be applied horizontally and immediately crossed off perpendicularly. Brushing
shall not be continued too long as otherwise brush marks may result.
8.5.5 White washing
The surface where white washing is to be applied shall be cleaned of all loose material and dirt. All
holes and irregularities of the surfaces shall be filled up with lime putty and shall be allowed to dry
out before application of the lime solution.
270
One coat of white wash shall consist of one stroke from top downwards, another from bottom
upwards over the first stroke and another from left to right and right to left before the vertical stroke
dries out. A second coat shall be applied and similarly a third coat shall be applied whenever the
Project Engineer and Executing Agency feels that more than two coats are required and the
Concessionaire shall do so without any extra cost to the Executing Agency. No brush marks shall
show on the finished surface.
8.5.6 Colour wash
For new work, the priming coat shall be of white wash with lime or with whiting. Two or more
coats shall then be applied on the entire surface till it represents a smooth and uniform finish. The
finished dry surface shall not be powdery and shall not readily come off on hand when rubbed.
Indigo or synthetic ultramarine blue shall, however, not be added.
8.5.7 Acrylic emulsion paint
Lime gauged cement plastered surfaces shall not be painted for at least one month after plastering.
All sample patch shall be painted to check alkali reaction if so desired by the Project Engineer and
Executing Agency. Painting shall be strictly as per manufacturer’s specification.
8.5.8 Oil bound distemper
Any unevenness in surface shall be made good by applying putty. The patched surface shall be
allowed to dry thoroughly before the coat of distemper is applied. One coat of distemper properly
diluted with thinner as specified by the manufacturer shall be applied by brush in horizontal strokes
followed immediately by vertical ones which together will constitute one coat. Two or more coats
of distemper as found necessary shall be applied to obtain even shade.
8.5.9 Chemical resistant, fire resistant and oil resistant paints
In general, method of application of these paints shall be strictly as per manufacturer’s

specification.
8.6 Painting of iron work
Paint to use for various items of work shall be of best quality and shall be obtained ready mixed in
sealed containers from approved manufacturer. The Concessionaire shall obtain the Project
Engineer and Executing Agency’s approval for the make and colour of the paint he proposes to use.
All surfaces shall be thoroughly cleaned of all dirt, loose particles and rust and approved prior to
application of paint. Workmanship shall conform to IS:1477 (Part I & II)
271
Specified number of coats shall be applied and atleast 24 hours shall elapse between the application
of successive coats. No painting shall be carried out on exterior work in wet weather or on surfaces
which are not entirely dry.
Painting rate shall include all necessary scaffolding, cradles and plant.
8.7 Protection
Furniture and other movable objects, equipments, fittings and accessories shall be moved, protected
and replaced upon completion of the painting work. All stationary items of equipments shall be
well covered so that no paint can fall on them. Work finished by other agencies shall be well
protected. All protection shall be as per instruction of the Project Engineer and Executing Agency.
8.8 Cleaning up
The Concessionaire shall upon completion of painting etc. remove all marks and make good
surfaces, where paint has spilled, splashed or splattered, including all equipments, fixtures, glass
furniture, fittings, etc. to the satisfaction of the Project Engineer and Executing Agency.
All painted surfaces shall be uniform and pleasing the appearance.

The colour, texture etc. shall match exactly with approved samples.
All stains, splashes and splatters of paint shall be removed from surrounding surfaces.
8.10 Painting of structural steel / miscellaneous steel
8.10.1 Scope
The specification covers painting of the structural/ miscellaneous steel supplied and erected either
by other agencies or by the Concessionaire for work under the scope of this contract. One shop coat
of red oxide zinc chromate primer including necessary touching up has already been completed by
the concerned agency. One coat of red oxide zinc chromate primer followed by a coat of
undercoating and two or more finishing coats of synthetic enamel paint as described hereunder are
only required to be provided under the item for painting structural / miscellaneous steel.
8.10.2 Type of structures to be painted
Painting shall be done on all exposed surfaces (including undersides wherever exposed) of various
structural steel members like columns, trusses, beams, roof girders, oil tanks, trestles, bracings,
crane girders, chequered plates, gratings, brackets, base plates etc. in the plant as directed by the
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Project Engineer and Executing Agency. It should be clearly noted that all structures are already
erected / placed in position or are under erection, hence the quoted rate by Concessionaire shall
account for all aspects involved in painting keeping in view the heights, available access to
members etc. It is advised that the Concessionaire should visit the site and get himself acquainted
with the nature of work completely including the extent and type of scaffoldings etc, required,
before quoting his rate.
8.10.3 Material
Paint shall be synthetic enamel paint conforming to IS:2932 of approved colour and brand.
8.10.4 Painting
In general, painting work shall be in accordance with IS:1477 (Part I & II).
Surface of steel work to be painted shall be thoroughly cleaned of all grease, oil dirt, rust, foreign
matter like cement splashings, etc. by suitable solvent and mild rubbing with abrasive paper/ hand
scrapping to the full satisfaction of the Project Engineer and Executing Agency. Clearing with
solvents/ scraping shall be limited to the affected areas only.
In cases where the existing primer is removed while cleaning the surface as detailed in 12.4.2,
damaged portions shall be provided with a coat of wash or etching primer on suitable chemical
pretreatment solutions and another coat of red oxide Zinc chromate primer. The payment for red
oxide primer will be made as per relevant item of Schedule of items.
After the surface is prepared in a manner described above, the primer coat shall be dry cut without
scratching or in any way damaging the primer coats and clean the surfaces from dust.
Over this dry surface apply an optimum coat of undercoating (synthetic enamel paint) by brush or
spray with minimum brush marks. Allow the film to dry hard, wet rub, cutting down to a smooth
finish (ensuring that at no place the undercoat is completely removed) Allow the water to evaporate.
The total dry film thickness of each coat shall be not less than 25 microns.
The paint shall be applied by brushing / spraying. Spraying shall be adopted with prior approval of
Project Engineer and Executing Agency generally on large surface areas. Paints shall be stirred
frequently to keep the pigment in suspension. Paint shall be ready mixed in original sealed
containers as packed by the paint manufacturers and no thinners shall be permitted. No painting
shall be done in frosty/ foggy / rainy weather or when humidity is high enough to cause
condensation on the surface to be painted. Paint shall not be applied when the temperature of the
surface to be painted is 5 deg or lower.
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Concessionaire shall provide and use sufficient number of drop clothes, covers, tarpaulins and other
screens to protect adjacent surfaces and shall remove all splatter and stains from such surfaces. The
Concessionaire shall also protect his own work.
Any and all damage to adjacent work or any part of the premises due to painting carelessness or
accidental performance of the Concessionaire shall be repaired or made good at the
Concessionaire’s expense.
Painting shall be discontinued when exposed to rain and dust storm and shall not commence until
the surfaces are perfectly dry and clean. Wherever practicable. Surfaces shall be painted when in
shade or when temperature is falling.
8.10.5 Cleaning up
The Concessionaire upon completion of painting etc. shall remove all marks and make surfaces
good, where paint has been spilled, splashed or splattered, including all equipment, fixtures, glass,
furniture, fittings, etc. to the satisfaction of the Project Engineer and Executing Agency.
a. All painted surfaces shall be uniform and pleasing in appearance.

b. The colour, texture, etc. shall match exactly with the approved samples.
c. All stains, splashes and splatters of paints shall be removed from surrounding surfaces.
274
Sub section - C9
Technical specification for fabrication and erection of structural steel works
275
Sub section - C9
Technical specification for fabrication and erection of structural steel works
Contents
9.1 Scope ............................................................................................................................................. 277

9.3 Applicable standard and codes ...................................................................................................... 279
9.4 Materials ....................................................................................................................................... 281
9.5 Fabrication .................................................................................................................................... 281
9.6 Welding ......................................................................................................................................... 284
9.7 Acceptance of welded structures................................................................................................... 290
9.8 Erection procedure ........................................................................................................................ 290
9.9 Steel grading ................................................................................................................................. 295
9.10 Stairs, railings and ladders ............................................................................................................ 296
9.11 Chequered plate ............................................................................................................................ 297
9.12 Ash storage silo / intermediate hopper .......................................................................................... 297
9.13 Sampling, testing and quality control ........................................................................................... 298
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Sub section - C9: Technical specification for fabrication and erection of structural steel works
9.1 Scope
This section of specification deals with the technical specifications needed for the fabrication and
erection of structural steel works coming under the scope of this contract. All connections shall be
of welded type unless specifically approved by the Project Engineer and Executing Agency
otherwise.
The specification cover providing, fabrication, erection, alignment etc. complete including
preparation of fabrication drawings of structural steel work involving rolled sections, pipes and
built up sections fabricated out of plates, rolled section and or combination of plates and rolled
sections in columns, beams, gantry girders, roof trusses, portals, purlins, space frames, shear
connector, monorails, galleries, wall beams, brackets, stub columns bracings, trestles, base plates,
chequered plate floorings, gratings with binders, walk way platform, ladders, stairs complete with
stringers, treads, landings, hand rails posts, erection bolts and nuts, permanent bolts and nuts,
dismantling, modification and re-erection of fabricated/erected steel, etc. including all sampling
and testing as given in Annexure-B for the areas of work as specified above.
The Concessionaire shall furnish all structural steel material, labour, plant, equipment,
consumables, scaffolding, tools, tackles, materials and everything that is required for complete
executions of the work on schedule in accordance with the drawings and as described herein and/or
as directed by the Project Engineer and Executing Agency.
9.2.1 Reference points and bench marks
The Concessionaire shall make his own arrangements for locating the coordinates and positions of
all work and reduced level (RL) at these locations based on two reference grid lines and one bench
mark which shall be furnished by the Executing Agency. The Concessionaire has to provide at site
all the required survey instruments to the satisfaction of the Project Engineer and Executing Agency
so that the work can be carried out accurately according to the specifications and drawings.
9.2.2 Safe working
The Concessionaire shall strictly follow, at all stages of fabrication, transportation and erection of
steel structures, the stipulations contained in the Indian standard safety code for erection of
structural steel work IS:7205 and the provisions of the safety rules as specified in the general
conditions of the contract for ensuring safety of men and materials. This shall include proper
approach and working platform during erection of the structures.
9.2.3 Drawings
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The fabrication drawings are to be prepared and furnished by the Concessionaire. These shall be
based on the design drawings. These drawings shall indicate complete details of fabrication and
erection including all splicing details, lacing details, weld sizes of lengths, detailing of all joints,
and bill of materials in the proforma approved by the Project Engineer and Executing Agency, and
all other customary details in accordance with standard structural engineering practice whether or
not given by the Executing Agency. He shall furnish along with the fabrication drawings, necessary
calculations regarding design of joints viz. Size and length of welds, dia and number of bolts, and
calculations justifying other fabrication details as well as design of erection and fabrication splices
in accordance with IS:800 and other relevant standards. He shall also furnish scheme of erection.
The fabrication drawings shall indicate identification (erection) marks for purposes of despatch and
erection etc.
In addition, the total quantity as well as abstract of quantities is indicated in the fabrication
drawings. The Concessionaire shall prepare a consolidated schedule of permanent bolts and nuts,
showing the length, size, weight and numbers required for each fabricated member.
Three copies of the detailed fabrication drawings including bolts and nuts schedule shall be
submitted by the Concessionaire for approval in the first instance along with Bill of materials
showing the description of members, their erection marks, quantity, etc. (Proforma to be approved
by the Project Engineer and Executing Agency). In case the approval accorded to the fabrication
drawings is subject to any modifications, additions, and alterations, the Concessionaire shall submit
two sets of the revised drawings for final approval after incorporating these changes.
In case the drawings are approved as submitted, he shall submit thirteen additional prints of such
approved fabrication drawings. In addition, the Concessionaire shall also be required to furnish
one reproducible copy of final fabrication drawings (as actually fabricated).
The design drawings may require revision either before or after the preparation and approval of
fabrication drawings. Such revision shall be duly incorporated in the fabrication drawings and
nothing extra shall be payable on this account for preparation / revision of fabrication drawings.
The Concessionaire is expected to make his own assumptions regarding the quantum of such
revisions involving preparation/revision of fabrication drawings, while quoting.
The fabrication work shall start only after the approval to the fabrication drawings is accorded by
the Project Engineer and Executing Agency.
Such approval shall, however, not relieve the Concessionaire of his responsibility for the safety of
the structure, good connections, erectability, etc.
9.2.4 Samples
Samples for checking the quality of materials procured by the Concessionaire and workmanship in
the execution of the works may be called for at any time by the Project Engineer and Executing
Agency. In case such samples are found to be of sub standard/unacceptable quality, the
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Concessionaire shall immediately discontinue use of such materials and workmanship and get fresh
samples approved by the Project Engineer and Executing Agency. Nothing shall affect the liberty
of the Project Engineer and Executing Agency to reject whole or portions of structures where such
defective materials and workmanship has already been used before detection.
9.2.5 Test at works
The Concessionaire shall arrange for all materials procured by him to be tested as and when
required and in the presence of the representative of Project Engineer and Executing Agency.
For structural steel test samples shall be cut out of the materials from the locations indicated by the
Project Engineer and Executing Agency and samples shall be prepared in accordance with the
requirements of Indian Standards Specifications for conducting such tests. For each set of tests
three samples shall be taken for tensile strength test and bend test. One set of tests will include test
of three individual specimens of samples.
9.2.6 Fabrication shop at project site
Fabrication shop of the Concessionaire at project site shall have all facilities required for carrying
out the work. The Concessionaire shall get the details of the shop approved by the Project Engineer
9.3 Applicable standard and codes
Except where otherwise specified herein or authorized by the Project Engineer and Executing
Agency, all items of work shall conform to the requirements of relevant latest Indian standards.
Any item of work, for which there is no Indian Standard available, shall conform to the latest British
standard (B.S.). The item of work shall be best of its kind and subject to approval of the Project
Engineer and Executing Agency. In case of conflict between this specification and those referred
to in the standard, the former shall prevail.
List of certain important codes and standards applicable to this work is given below. However the
applicable standards and codes shall be as per but not limited to the list given below.
9.3.1 Materials
IS : 808 Rolled steel, beam, channel and angle sections

IS : 2062 Structural steel (fusion welding quality)
IS : 1363 Hexagon head bolts, screws and nuts of production grade C.
IS : 1364 Hexagon head bolts, screws, and nuts of production grade A & B.
IS : 1367 Technical supply conditions for threaded fasteners.
IS : 1161 Specification of steel tubes for structural purposes.
IS : 2016 Specification for plain washers.
IS : 814 Specification for covered electrodes for metal arc welding for weld steel.
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IS : 1852 Specification for rolling and cutting tolerances for hot rolled steel
products.
IS :2074 Ready mixed paints, red oxide zinc chromate primer.
IS : 3502 Specifications for chequered plate.
IS : 383 Specification for coarse and fine aggregates from natural sources for
concrete.
IS : 1566 Specification for hard-drawn steel wire fabric for concrete reinforcement.
IS : 3757 Specification for high strength structural bolts.
9.3.2 Codes of Practice
IS : 800 Code of practice for construction in steel.

IS : 816 Code of practice for use of metal arc welding for general construction.
IS : 9595 Code of procedure of manual metal arc welding of mild steel.

IS : 817 Code of practice for training and testing of metal arc welders
IS : 1811 Qualifying tests for metal arc welders (engaged in welding structures other
than pipes).
IS : 1182 Recommended practice for radiographic examination of fusion-welded
butt joints in plates.
IS : 1477 Code of practice for painting of ferrous metal in buildings and allied
finishes.
IS : 3696 Safety code of scaffolds and ladders.
IS : 7293 Safety code for working with construction machinery.
IS : 7205 Indian Standard safety code for erection of structural steel.
IS : 7215 Tolerances for fabrication steel structures.
IS : 12843 Tolerance for erection of structural steel.
IS : 4353 Recommendation for submerged arc welding of mild steel and low alloy
steels.
SP : 6 ISI Hand book for structural engineers. (Part 1 to 7)
9.3.3 Standards for testing
IS: 1608 Method of tensile testing of steel products other than sheets, strip, wire
and tube.
IS : 1599 Method of bend tests for steel products other than sheets, strip, wire and
tube.
IS : 228 Methods of chemical analysis of pig iron, cast iron and plain carbon and
alloy steel
IS : 2595 Code of practice for radio graphic testing.
IS : 1182 Recommended practice for radiographic examination of fusion welded
butt joints in steel plates.
IS : 3664 Code of practice for ultrasonic testing by pulse echo method.
IS : 3613 Acceptance tests for wire flux combination for submerged arch welding.
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IS : 3658 Code of practice for liquid penetrant flow detection.
IS : 5334 Code of practice for magnetic particle flaw detection of welds.
9.4 Materials
Structural steel rolled sections and plates shall conform to specified grade of IS:2062. However
rolled sections and plates upto 20mm conforming to IS:226 may be used in place of grade-A
of IS:2062. Pipes used in Handrails, embedments etc. Shall conform to IS:1161. Chequered plate
shall conform to IS:3502. High strength steel shall conform to IS:8500 of specified grade. All other
materials shall be as per the list of standards codes given above or mentioned elsewhere in the
relevant sections.
All steel sections and plates shall be straight, sound, free from twists, cracks, flaws, laminations,
rough, jagged and imperfect edges and other defects.
In case any defect like laminations is noticed in the steel sections and plates during fabrication and
erection, the same shall be brought to the notice of the Project Engineer and Executing Agency.
These sections and plates shall be rejected unless specifically approved for acceptance by the
9.5 Fabrication
The fabrication and erection of works shall be carried out generally in accordance with IS:800 as
well as the stipulations contained in this specification. All materials shall be completely fabricated
at his own shop or at the shop established by him at project site and finished with proper connection
materials for ready assembly in the field. Check list format, inspection certificate for fabrication,
erection, alignment and protocol for handling over of structural steel shall be submitted by the
Concessionaire in the form as agreed to by the Project Engineer and Executing Agency. Fabrication
work shall be taken up based on the approved fabrication drawings.
9.5.1 Cutting plans
Fabrication work shall be taken up based on the fabrication drawings duly approved by the Project
Engineer and Executing Agency. The Concessionaire shall prepare necessary cutting plans before
commencement of fabrication for all fabrication drawings.
9.5.2 Straightening
All steel material shall be straight and free from bends or twists. If the sections are distorted or
twisted during transit, storage, etc. They shall be straightened and/or flattened by straightening
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machine at ambient temperature, though minor kinks or bends may be corrected by limited heating
under careful supervision.
9.5.3 Bending
The bending of plates and sections to specially required shapes shall be done either on appropriate
machine or by angle smithy and black smithy processes.
9.5.4 Cutting
Cutting may be effected by shearing, cropping, sawing or by gas cutting by mechanically controlled
torch. Gas cutting by hand may only be used when specifically authorized in writing by the Project
Engineer and Executing Agency. The edges of all plates shall be perfectly straight and uniform
throughout. Shearing, cropping and gas cutting shall be clean, square and free from distortion and
burrs, and should the Project Engineer and Executing Agency find it necessary the edges shall be
ground afterwards by the Concessionaire.
9.5.5 Grinding
All the edges cut by flame shall be ground before they are welded. Ends of all bearing stiffeners
shall be ground to fit tightly at both top and bottom. The maximum permissible gap between the
bearing stiffeners and the flanges shall not be more than 0.2 mm locally.
In case of gantry girders, the bottom of the knife-edge support shall be accurately ground to provide
effective bearing on the column bracket with a clearance not exceeding 0.2 mm locally at any place.
The top surface of the column bracket shall also be ground similarly. The column splices and butt
joints of struts and compression members shall be accurately ground and closely butted over the
whole section with tolerance not exceeding 0.2 mm locally at any place. Notwithstanding the above,
full load shall be transferred through welds.
The ends of shafts together with attached gussests, angles, channels, etc. After welding together
shall be accurately ground so that the parts connected, butt over the entire surface of contact. Care
shall be taken to see that these connecting angles or channels are fixed with such accuracy that they
are not reduced in thickness by grinding by more than 1 mm.
The slab bases shall be similarly ground over the bearing surface and shall have effective contact
with the end of the shaft. The bearing face which is to be grouted direct to a foundation need not
be ground if such face is true and parallel to the upper face. To facilitate grouting and escape of air,
holes shall be provided wherever necessary in column bases.
9.5.6 Clearances
The erection clearance for cleated ends of members connecting steel to steel shall not be greater
than 2 mm at each end unless specifically approved by the Project Engineer and Executing Agency.
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9.5.7 Holes
Holes through more than one thickness of material for members, such as compound stanchion and
girders, flanges, shall where possible, be drilled after the members are assembled and tightly
clamped or bolted together. Sub-punching may be permitted before assembly, provided the holes
are punched 3 mm less in diameter than the required size and reamed after assembly to the full size.
Punching shall not be adopted where the thickness of metal exceeds 16 mm.
When holes are being drilled in one operation through two or more separable parts, those parts,
when so specified by the Project Engineer and Executing Agency shall be separated after drilling
and burrs removed.
Holes in connecting angles and plates, other than splices, also in roof members and light framing,
may be punched full size through material not over 12 mm thick, except where required for close
tolerance.
Matching holes for rivets and blacks bolts shall register with each other so that a gauge of 1.5 mm
or 2.0 mm (as the case may be, depending on whether the diameter of the bolt is less than or more
than 25 mm) less in diameter than the diameter of the hole will pass freely through the assembled
members in a direction at right angles to such members. Finished holes shall not be more than 1.5
or 2.0 mm (as the case may be) larger in diameter than the diameter of the black bolt passing through
them unless otherwise specified by the Project Engineer and Executing Agency.
Holes for bolts shall not be formed by a gas cutting process, except in special cases with specific
permission of the Project Engineer and Executing Agency. Wherever a horizontal member is likely
to collect water, suitable holes for drainage shall be provided.
9.5.8 Notches
The ends of all joints, beams and girders shall be cut truly square unless required otherwise and
joist flanges shall be neatly cut away or notched where necessary, the notches being kept as small
as possible.
9.5.9 Assembly
The component parts shall be assembled in such a manner that they are neither twisted nor
otherwise damaged and shall be so prepared that the specified chamber, if any, is provided. In
order to minimize distortion in a member the component parts shall be positioned by using clamps,
clips, dogs, jigs and other suitable means and fasteners (bolts and welds) shall be placed in a
balanced pattern. If the individual components are to be bolted, parallel and tapered drifts shall be
used to align the parts so that the bolts can be accurately positioned.
Items like roof trusses, galleries, plate girders etc. shall be trial assembled keeping in view the
actual site conditions, prior to despatch to site for erection so that they can be conveniently
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preassembled before erection or conveniently preassembled during erection. Necessary match
marks shall be made on these components before disassembly in the shop and despatching.
For columns which are fabricated in two or more parts, controlled assembly shall be carried out in
the fabrication yard before despatch to the erection site.
9.5.10 Bolting
Every bolt shall be provided with a washer under the nut so that no part of the threaded portion of
the bolt is within the thickness of the parts bolted together.
Flat washers shall be circular of a diameter 2.5 times that of bolt and of suitable thickness. Where
bolt heads/nuts bear upon the beveled surfaces they shall be provided with the square tapered
washers of suitable thickness to afford a seating square with the axis of the bolt.
All bolts and nuts shall be of steel, with well-formed hexagonal heads unless specified otherwise,
forged from the solid and shall be dipped in hot boiled linseed oil as soon as they are made. The
nuts shall be good fit on the bolts and two clear threads shall show through the nut when it has been
finally tightened up.
Notwithstanding anything to the contrary contained in IS:1363, IS:1364, and IS:1367, the
unthreaded length of the bolt shall be equal to total thickness of metal being bolted together plus 2
mm. The threaded length shall be equal to at least the diameter of bolts plus 6 mm.
9.6 Welding
The works shall be done as per approved fabrication drawing which would clearly indicate various
details of joints to be welded, type of weld, length and size of weld, whether shop or site weld.
Symbols for welding on fabrication drawings shall be according to IS:813. Efforts shall be made
to reduce site welding so as to avoid improper welding due to constructional difficulties.
9.6.1 Welding of structural steel work
Welding of Structural Steel shall be done by an electric arc process. The procedure to be followed,
materials, plant and equipment to be used, testing and inspection procedures to be applied shall be
subject to the approval of the Project Engineer and Executing Agency and shall conform generally
to relevant acceptable standards viz. IS:816, IS:9595, IS:814, IS:4354 and Indian Standard Hand
Book for metal arc welding, and other standard codes of practice internationally accepted.
Submerged-Arc-Welding/MIG (using Carbon dioxide) welding process employing semi-automatic

welding machine and fully automatic welding machine (of approved make) shall be used for
welding all butt joints and longitudinal fillet welds (connecting flange with web) respectively for
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fabrication of columns, framing beams & crane gantry girders, unless manual arc welding is
specifically approved by the Project Engineer and Executing Agency. Necessary jigs & fixtures
and rotation of structures shall be so arranged that vertically down-hand position of welding
becomes possible.
‘Open-Arc-Welding’ process employing coated electrodes shall be employed for fabrication of

other welded connections not covered under 6.02.02 and field welding.
Wherever welding is done for assembling the components of structures, the job shall be so
positioned that down hand welding is possible. In cases where positioning of job is not possible
other manual welding positions could be resorted to.
Any structural joint shall be welded only by those welders who are qualified for all welding
procedures and positions required in such joint that is welded. The entire weld of any structure
joint shall be made by one welder.
Each welder shall be assigned an identification mark and such mark shall be marked on the structure
adjacent to the weld on completion of any structural welded joint.
The Concessionaire shall maintain records of all the welders identification marks, the joints welded
by each welder, the welding procedure adopted, welding machine employed, pre and post heating
done & any non destructive test done and stress relieving heat treatment performance on such joints.
All such records for entire welding operation shall be accessible to the Project Engineer and
Executing Agency for scrutiny & such record shall be countersigned by Project Engineer and
Executing Agency for welding work accomplished in the preceding months as token of acceptance.
But such acceptance shall not relieve the Concessionaire of his responsibility regarding adequacy
& safety of welding operation.
9.6.2 Edge preparation for welding
Proper edge preparation shall be made for jointing of materials before welding. Suitable edge
preparation shall be done for all processes of welding except for square-butt welds. Type of edge
preparation shall depend on the thickness of parent materials that are to be joined. The edge forms
shall be chosen to suit the design, technology and production conditions and shall be subject to the
approval of the Project Engineer and Executing Agency. The edge form of weldments shall be
prepared either by machines or by automatic gas cutting with surface roughness of the welding area
not exceeding Rs.50/- All edges cut by flame shall be ground before they are welded.
9.6.3 Electrodes
The electrodes used for welding shall be of suitable type and size depending upon specifications of
the parent materials, the method of welding, the position of welding and quality of welds desired
e.g. normal penetration welds or deep penetration welds. However, only low Hydrogen electrodes
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shall be used for plates thickness above 40 mm for IS:2062 steel and for all thickness of high
strength steel conforming to IS:8500.
All low hydrogen electrodes shall be baked and stored before use as per manufacturers
recommendation. The electrodes shall be rebaked at 250°C - 300°C for one hour and later on cooled
in the same oven to 100°C. It shall be transferred to an holding oven maintained at 60°C - 70°C.
The electrodes shall be drawn from this oven for use. Rutile type electrodes shall not be kept in the
same oven.
Where coated electrodes are used they shall meet the requirements of IS:814 and relevant ASME-
SEC IX and IIC. Coating shall be heavy to withstand normal conditions of handling and storage.
They shall be free from all defects which would interfere with performance of electrodes.
Only those electrodes which give radiographic quality welds shall be used for welds which are
subjected to radiographic testing.
Where bare electrodes are used these shall correspond to specification of the parent material. The
type of flux-wire combination for submerged arc welding shall conform to the requirements of
IS:3613. The electrodes shall be stored properly and the flux shall be baked before use in an oven
in accordance with the manufacturer’s requirements as stipulated.
Specific approval of the Project Engineer and Executing Agency shall be taken by the
Concessionaire for the various electrodes proposed to be used on the work before any welding is
started.
9.6.4 Preheating inter-pass temperature and post weld heat treatment
Mild steel plates conforming to IS:2062 and thicker than 20 mm, may require preheating of the
parent plate prior to welding as mentioned in Table - 1. For high strength steel conforming to
IS:8500 the minimum preheat temperature shall be as specified in Table - 1. However, higher
preheat temperature may be required as per approved welding procedure and same shall be
followed. In welding materials of unequal thickness, the thicker part shall be taken for this purpose.
Base metal shall be preheated, not withstanding provisions of IS:9595 to the temperature given in
Table - 1 prior to welding or tack welding. When base metal not otherwise required to be preheated
is at a temperature below 0 deg. C it shall be preheated to at least 20 deg.C, prior to tack welding
or welding. Preheating shall bring the surface of the base metal to the specified preheat temperature
and this temperature shall be maintained as minimum interpass temperature while welding is in
progress.
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Table - 1: Minimum Preheat Interpass Temperature for Welding
Welding used
Thickness of thicker Other than low IS:8500 steel Low hydrogen electrodes/ IS:8500
part at point of hydrogen or submerged arc welding Steel
welding electrode IS:2062 steel
IS:2062 steel
1 2 3 4 5
Upto 20 mm including None welding by None None
this
Over 20 mm including 66ºC electrode not 20ºC 66ºC
allowed
Over 40 mm to 63 mm not allowed - 66ºC 110ºC
including
Over 63 mm not allowed - 110ºC 150ºC
Preheating may be applied by external flame which is non-carbonising like LPG, by electric
resistance or electric induction process such that uniform heating of the surface extending upto a
distance of four times the thickness of the plate on either side of the welded joint is obtained.
Thermo-chalk, thermo-couple or other approved methods shall be used for measuring the plate
temperature.
All butt welds with plater thicker than 50 mm require post weld heat treatment as per procedure
given in AWS D-1.1. Post heating shall be done upto 600 deg c and rate of application shall be 200
deg C per hour. The post heat temperature shall be maintained for 60 minutes per 2.5 cm thickness.
For maintaining slow and uniform cooling, asbestos pads shall be used for covering the heated
areas. The Concessionaire shall submit and finalize post weld heat treatment procedure at the time
of finalization of quality plans.
9.6.5 Sequence of welding
The sequence of welding shall be carefully chosen to ensure that the components assembled by
welding are free from distortion and large residual stresses are not developed. The distortion should
be effectively controlled either by a counter effect or by a counter distortion. The direction of
welding should be away from the point of restraint and towards the point of maximum freedom.
Each case shall be carefully studied before finally following a particular sequence of welding.
Butt weld in flange plates and/or web plates shall be completed before the flanges and webs are
welded together.
The beam and column stiffeners shall preferably be welded to the webs before the web and flanges
are assembled unless the web and flanges to the beam or column are assembled by automatic
welding process.
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Approval of welding sequence and procedure shall not relieve the Concessionaire of the
responsibility for the correct welding and for minimizing the distortion in the finished structure
which in no case shall exceed that laid down in Indian Standards.
All welds shall be finished full and made with correct number of runs, the welds being kept free
from slag and other inclusions, all adhering slag being removed from exposed faces immediately
after such run.
Current shall be appropriate for the type of electrode used. To ensure complete fusion, the welding
procedure should go proper and rate of arc advancement should not be so rapid as to leave the edges
unmelted.
Puddling shall be sufficient to enable the gases to escape from the molten metal before it solidifies.
Non-uniform and heating and cooling should be avoided to ensure that excessive stresses are not
locked up resulting ultimately in cracks.
The welding shrinkage shall be minimized by adopting the correct welding procedure and method.
In long and slender members extra length should be provided, at the time of fabrication, for
shrinkage.
The ends of butt welds shall have full throat thickness. This shall be obtained on all main butt welds
by the use of runoff and run on pieces adequately secured on either side of main plates. Additional
metal remaining after the removal of extension pieces shall be removed by grinding or by other
approved means and the ends and surface of the welds shall be smoothly finished.
The fusion faces shall be carefully aligned. Angle shrinkage shall be controlled by presetting.
Correct gap and alignment shall be maintained during the welding operation.
All main but welds shall have complete penetration and except where it is impracticable they shall
be welded from both sides, back surface of the weld being gauged out clean before first run of the
weld is given from the back. However, partial penetration butt weld shall be permitted, when
specifically shown in the fabrication drawings.
Intermittent welds shall not be permitted without the approval of the Project Engineer and
Executing Agency. These shall be permitted only when specifically approved in the fabrication
drawings.
9.6.6 Testing of welders
All the welders to be employed for the job shall have to qualify the appropriate tests laid down in
IS:817 and IS:1181. If the welder fails in these tests, two further set of tests shall be undertaken
and the welder to qualify must pass both these sets of tests.
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The Project Engineer and Executing Agency also reserves the right to have any welder retested at
any time. All the necessary arrangements required for the testing of welders are to be provided by
the Concessionaire.
9.6.7 Inspection of welds
 Visual inspection
100 percent of the welds shall be inspected visually for external defects. Dimensions of welds shall
be checked. The lengths and size of weld shall be as per approved fabrication drawings. It may be
slightly oversized but should not be undersized. The profile of weld is affected by the position of
the joint but it should be uniform. The welds should have regular height and width of beads. The
height and spacing of ripples shall be uniform. The joints in the weld run shall as far as possible be
smooth and should not show any humps or craters in the weld surface. Welds shall be free from
unfilled craters on the surface, under-cuts, slags on the surface and visible cracks. Such inspection
shall be done after cleaning the weld surface with steel wire brushes and chisel to remove the spatter
metal, scales, slag etc. If external defects mentioned above are noticed, there is every possibility of
internal defects and further radiographic / ultrasonic examination shall be undertaken as per Indian
Standards. Weld gauges shall be used to measure the size of the welds.
 Mechanical testing
Test plates shall be incorporated on either side of 10% of main butt welds & the weld shall be
continuous over the test plate. The test plate shall be cut from extensions of the main plates and
shall be fixed so that metal lies in the same direction as that of the main plate. Test plates shall be
prepared and tested in accordance with the accepted Standards, in the presence of the Project
Engineer and Executing Agency or his authorized representative. All testing equipment and
facilities for carrying out these tests shall be provided by the Concessionaire should any of these
tests fail, further radiographic examination of the welds in question on the main members, shall be
undertaken by the Project Engineer and Executing Agency as specified in the specification. These
tests for the test plates and radiographic examination are additional to those contemplated under
routine inspection and testing. The Concessionaire shall carry out these additional radiographic
tests as per normal testing procedure.
 Non-destructive and special testing
In addition to the normal supervision and testing procedure, radiographic/ultrasonic or other non-
destructive examination shall be carried out, as stipulated in the Fabrication/Erection checklist on
butt or fillet welded joints and/or on test specimens, as per Annexure - B. All test of welds shall be
carried out by the Concessionaire at his own cost as per Annexure - B. However, for checking the
quality of weld, the Executing Agency shall carry out additional tests at his own cost. The
Concessionaire shall provide necessary supporting facilities free of cost, as may be required by the
Project Engineer and Executing Agency, including cordoning of radiation zone while Radiography
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testing is in progress. Prepared etched section of the welds may be required for examination. The
Concessionaire shall, at his own cost, provide these prepared sections.
The case of failure of any of the tests, the cost of re-test of that portion of the test shall be recovered
from the Concessionaire.
Rectification of defective welding work wherever defects like improper penetration, extensive
presence of blow holes, undercuts, cracking, slag inclusion, etc. are noticed by visual inspection /
other tests, the welds, in such location shall be removed by gouging process. The joints shall be
prepared again by cleaning the burrs and residual matters with wire bushes and grinding, if
necessary, and rewelded. The gouging shall as far as possible be done using gouging electrodes.
Flame gouging shall be resorted to only in special cases with specific permission of the Project
9.7 Acceptance of welded structures
The acceptance of the welded work shall depend upon current dimensions and alignment, absence
of distortion in the structure, satisfactory results from the inspection and testing of the joints and
the test specimens as per quality check list and upon general workmanship being good meeting the
tolerance requirements given in the quality check list as per Annexure - B.
9.8 Erection procedure
9.8.1 Erection marks
The erectability of the structures shall be checked by the Concessionaire before commencement of
the fabrication work to avoid future modification.
Before any steel work leaves the Concessionaire’s fabrication site, it shall be suitably marked in
accordance with the approved fabrication drawings and according to an approved marking plan.
The erection marks assigned to various components of the structural steel work, excepting
secondary beams, shall also contain an erection sequence number indicating the sequence in which
the various components are to be erected.
Erection marks shall be clearly painted on the work item, each piece being marked in at least two
places. Each piece shall also have its weight marked thereon. In order to help identification, each
erection piece, i.e. erection mark item, shall bear its items erection mark and erection sequence
number. Erection marks shall be painted on the structures, during the process of fabrication to
facilitate their identification during inspection. Where a number of components are identical and
bear the same erection mark, these components shall be further identified by assigning numerals in
addition to the common erection mark.
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The centre lines of all column, elevations and girder bearings shall be marked on the sections with
the utmost care to ensure proper alignment and assembly of the pieces at site.
9.8.2 Erection
The Concessionaire shall submit for approval of the Project Engineer and Executing Agency his
Erection Scheme for the erection of all types of structures. Erection shall commence only after
approval of the Concessionaire’s proposed erection scheme.
The erection scheme shall give full details of the method of handling, transport, hoisting and
erection including false work/staging, temporary bracing, guying temporary strengthening etc. It
will also give the complete details of the quantity and capacity of the various items of erection
equipment that will be used. Any modifications to the erection scheme as directed by the Project
Engineer and Executing Agency for various reasons or due to the interference with the work of
other agencies shall be incorporated by the Concessionaire.
The Concessionaire shall examine the site conditions and transportation clearances before deciding
whether columns are to be fabricated and erected in one piece or more than one piece. Erection of
structures is to be carried out preferably with a crane and in case this is not possible, only the upper
portion of the columns can be erected with a derrick. Further, the erection of columns and portals
etc. shall be carried out in one single piece as far as practicable. No column shall be fabricated and
erected in more than 3 pieces. Proper splicing shall be provided at the erection joints indicated in
fabrication drawings. When erection joints are provided in columns, their location shall generally
be just above a floor level.
The structural steel shall as far as practicable be erected frame wise. Thereafter, the frames shall be
progressively aligned and all erection welding completed. The secondary beams shall thereafter be
erected, aligned and welded completely as per the approved schedule of work. Touch up painting
in these areas shall be completed and as soon as a particular portion of the structure/floor is
completed in all respects, it shall be handed over to other Concessionaires for carrying out other
civil works as well as mechanical/ electrical erection works. Conveyor galleries shall generally be
erected as a completely fabricated box, i.e. the bottom chord and bracings, top chord and bracings,
side vertical posts and bracings, end portals and roof-trusses shall be completely welded prior to
erection. The inside sheeting runners and roof sheeting purlins may be erected individually.
9.8.3 Protection against damage in transit
All steel work shall be efficiently and sufficiently protected against damage in transit to site from
any cause whatsoever. All projecting plates or bars and ends of members at joints shall be stiffened,
all straight bars and plates shall be bundled, all screwed ends and machined surfaces shall be
suitably packed and all bolts, nuts, washers and small loose parts shall be packed separately in cases
so as to prevent damage or distortion during transit. Should there be any distortion of fabricated
members the Concessionaire shall immediately report the matter to the Project Engineer and
Executing Agency. Distorted steel received from stores or distorted during transport from stores
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to the fabrication yard shall not be used in fabrication unless the distortions are minor which in the
opinion of the Project Engineer and Executing Agency can be removed by acceptable methods.
These distortions shall be rectified by the Concessionaire by cold-bending. If heating is necessary

to rectify the defects, the details of the procedure shall be intimated to the Project Engineer and
Executing Agency whose approval shall be taken before such rectification. The temperature of teat
treatment shall not exceed the limits beyond which the original properties of the steel are likely to
be impaired.
If in the opinion of the Project Engineer and Executing Agency the steel has been unduly bent in
transit from the project stores to the fabrication yard or during handling by the Concessionaire
which cannot be rectified in the opinion of the Project Engineer and Executing Agency, such steel
shall be counted as wastage .
9.8.4 Stability of structures
The Concessionaire shall be responsible for the stability of the structure at all stages of its erection
at site and shall take all necessary measures by the additions of temporary bracings and guying to
ensure adequate resistance to wind and also to loads due to erection equipment and their operations.
Guying and bracing shall be done in such a way that it does not interfere with the movement or
working of other agencies working in the area. For the purpose of guying, the Concessionaire shall
not use other structures in the vicinity which are likely to be damaged by the guy.
 Setting column bases
Column bases shall be set so that the column load is uniformly transmitted to the foundation. The
Concessionaire shall carefully check the location and layout of anchor bolts embedded in
foundations constructed to ensure that the structures can be properly erected as shown on the
drawings.
The Concessionaire shall be responsible for the correct alignment and leveling of all steel work on
site to ensure that the columns are in plumb. The permissible erection tolerances for the structural
members are given in Table ‘A’ given at the end of this specification.
Before erection of columns on their foundations, the top surface of base concrete shall be
thoroughly cleaned with wire brushes and by chipping to remove all laitance and loose material.
The Concessionaire shall also be responsible to provide all packing and shim, plates. No steel
structure shall be erected on their foundation unless such foundations have been certified fit for
erection of steel by the Engineer. Adequate number of air release holes and inspection holes shall
be provided in the base plate. The grouting/under pinning of base plate and chipping of foundation
to desired level are also in scope of Concessionaire.
9.8.5 Painting
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After inspection and issue of test and acceptance certificate, all steel surfaces shall be painted or
otherwise treated. Except where encased in concrete, all steel work shall be given one coat of
approved metal protection as may be specified, applied evenly and thoroughly and well worked
into the joints and other open spaces.
Materials
i) The touch-up primers and paints shall consist of Red oxide Zinc Chromate conforming to
the requirements of IS:2074 with a pigment to be specified by the Executing Agency.
However, the Concessionaire may have to use other type of primer wherever specified.
ii) The contents of paint drums shall be thoroughly mixed so that no material remains at the
bottom before the paint is used and the paint shall be stirred at regular intervals while being
applied.
iii) The primers should not be diluted or thinned except as hereinafter specifically provided.
Where the paint has thickened due to loss of Solvent by evaporation in partially used tins
it may be brought to consistency for application, in consultation with the manufacturer who
shall give necessary information particularly with regard to appropriate viscosity.
iv) Material shall be of best quality available and procured directly from approved
manufacturers. Samples shall be submitted to the Executing Agency or approval before
procurement.
 Preparation of surface
i) The surface preparation shall be done in accordance with IS:1477 (Part I) Code of Practice
for Finishing of Ferrous Metals in Buildings: Painting and Allied Finishes: Part I
(Operation and Workmanship).
ii) The surface shall be cleaned and degreased in accordance with one or more of the methods
given in Clause 6.1 of IS:1477 (Part I).
iii) The surface shall be derusted and de-scaled either mechanically or chemically by one or
more of the methods given in Clause 6.2 of OS:1477 (Part I) to the satisfaction of the
Executing Agency. However flame cleaning, sand, blasting, and shot blasting are excluded
from the scope of Concessionaire.
iv) While cleaning with power wire-brush, care shall be taken not to do it excessively, since
mill scale easily gets burnished to a smooth even surface to which paints does not adhere,
and this will be detrimental to the performance of paint. All accessible weld flux and
splatter shall be removed by power tools.
 Application of priming coat, touch-up paint
i) Primers are generally applied by brushing. In areas which are difficult to reach either by
brushing or spraying, daubers, mops or both may be used by dipping the same in paints and
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pulling or pushing them through the narrow spaces unless otherwise specified one coat of
primer of 25 micron thickness shall be applied in shop.
ii) During the painting, the air temperature shall be well above the dew point and not less than
4 C and relative humidity not greater than 80%. The time of painting shall be such that
moisture does not condense on the structure before or during painting or until the painting is
dry.
iii) Primer coats shall be applied without any time lag after the pre-cleaning or pretreatment and
care shall be taken to ensure that paint is not applied to damp surface (in early morning, under
humid conditions dew etc.)
iv) Surfaces of fabricated steel where shop priming coat has been removed or damaged during
transit or defaced during welding including site welded locations shall be cleaned and applied
with touch up primer coat of paint.
 Shop connections
i) Surfaces to be permanently in contact shall receive a priming coat immediately prior to

being jointed together at the works except where jointed by welding.
ii) Galvanised steel shall not be prepared or painted at site.
Machined, sliding or rocking surfaces of casting blocks, slabs or pins shall be coated with a mixture
of white lead and tallow after the work has been inspected and approved by the Executing Agency.
Molybdenum disulphate (grease) will be used in rider pin connections.
Surfaces not in contact, but inaccessible after shop assembly shall receive two coats of shop paints,
positively of different colours or such material to prove use of two coats before assembly. This
does not apply to the interior of sealed hollow sections.
Shop contact surfaces shall be cleaned by effective means before assembly, but not painted.
In the case of surface to be welded, the steel shall not be painted or metal coated within minimum
50 mm distances of any edges to be welded, if the paint specified or the metal coasting would be
harmful to welders or impair the quality of the welds. Welds and adjacent parent metal shall not
be painted prior to deslaggings, inspection and acceptance.
Site preparation of contract surface
i) The paint, on all contact surfaces, which was applied in the fabrication shop shall be carefully
removed and a fresh coat of priming paint shall be applied to all surfaces in permanent
contact, and the surfaces shall be brought together while the paint is still wet.
ii) The Concessionaire shall provide and use sufficient number of drop cloths, covers, tarpaulin
and other screens to protect adjacent surfaces and shall remove all spatter and stains from
such surfaces. The Concessionaire shall also protect his own work.
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iii) The Concessionaire shall provide and use sufficient number of drop cloths, covers, tarpaulin
and other screens to protect adjacent surfaces and shall remove all spatter and stains from
such surfaces. The Concessionaire shall also protect his own work.
iv) Painting shall be discontinued during rain and dust-storm and shall not commence until the
surfaces are perfectly dry and clean. Wherever practicable, surfaces shall be painted when
in shade or when the temperature is failing.
v) Welds and adjacent metal shall not be painted or touched up prior to deslagging inspection
and approval.
vi) Parts of the steel structures to be encased in concrete shall not be painted.
vii) One coat of primer and touch-up paint shall be applied except for the item which shall be not
dip galvanized.
9.9 Steel grading
All grating units shall be rectangular in pattern and welded grating assembly. The size and the
spacing of the bearing bars and cross bars shall be as approved in detailed drawings. The detail
fabrication drawings for gratings shall be prepared by Concessionaire on the basic of approved
design for grating.
The gratings shall be made up in panel units designed to coincide with the span of the structural
steel framing as indicated in the drawings or as directed by the Project Engineer and Executing
Agency. The size of each panel shall be as approved by Project Engineer and Executing Agency.
The grating unit shall be accurately fabricated and finished, free from wraps, twists or any defects
that would impair their strength, serviceability and appearance.
Grating work shall include cut outs and clearance opening for all columns, pipes, ducts, conduits
or any other installation penetrating through the grating work. Such cut outs and clearances shall
be treated as follows.
The gratings shall be notched, trimmed and neatly finished around flanges and webs of the columns,
moment connections, cap plates and such other components of the steel structures encountered
during the placement of the gratings. In all such cases, the trimming shall be done to follow the
profile of the components encountered. After trimming, the binding strip shall be provided on the
grating to suit the profile so obtained.
Opening in gratings for pipes or ducts that are 150 mm in size or diameter or larger shall be provided
with steel bar toe plates of not less than 5 mm thickness and appropriate width, set flush with the
bottom of the bearing bars.
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Penetrations in gratings that are more than 50 mm but less than 150 mm in size or diameter shall
be welded with plates of size shown in the detailed drawings set flush with the bottom of the grating
panel.
Unless otherwise indicated on the drawings, grating units to all penetrations shall be made up in
split section, accurately fitted and neatly finished to provide for proper assembly and erection at
the job site.
Grating units shall be provided with all necessary clips, bolts, nuts and lock washers required for
proper assembly and rigid installation and fastening to abutting units and supporting structural steel
framing members.
All fabricated grating section and accessories shall be primed and finish painted in the shop prior
to erection at site. Painting shall consist of two coats of red lead primer and two coat of black
enamel finish.
Prior to painting all surfaces shall be cleaned free from rust, millscale, grease, oil, or any other
foreign matter that might affect the adherence of the paint by sand blasting. While the primer shall
be applied by spray guns or by brushes, the final coat of finished paint shall necessarily be applied
by means of spray guns only.
The applied coatings shall be uniform, free from voids and streaks, drilled or punched holes shall
be touched up prior to erection or assembly.
Maximum deviation in linear dimension from the approved dimension shall exceed 12 mm.
9.10 Stairs, railings and ladders
All stairs and intermediate landings shall be constructed to size dimensions and design, as indicated
on the detailed drawings. Such stairway shall be fabricated as a complete unit which shall include
struts, hangers, posts, cross bracings, cleats and accessories, as required for connection to structural
steel framing and concrete.
Stair treads shall be furnished complete with punched and slotted carrier plates attached ready to
bolt to stair stringers. Treads shall be provided with antislip nosing using chequered plate and set
flush with the stair treads.
Pipe handrails, as specified in detailed drawings shall be assembled with flush type fittings and
welded joints, ground and polished smooth. Railings shall be provided with all necessary fittings
posts brackets, bolts, plates and similar accessories as shown on the approved drawings and as
required for proper installation.
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Hand rails shall be of standard weight black steel pipes of flush welded construction, ground
smooth using 32 mm nominal bore medium class pipes with double rail about 1.25 metre above
platform level and pipe posts spread not more than 1.5 metres apart.
Smooth uniform curves and bends are to be provided at stair returns and also wherever
specified/required. The open ends of all pipe posts shall be plugged and welded. A minimum radius
of 3 times the pipe diameter shall be provided at all points of direction changes in the hand rails.
Vertical ladders shall be as called for on the approved drawings. The ladders shall be provided with
support arms formed of bent steel plate or clip angles. Where shown on the drawings the ladders
shall have loose neck supports, designed to form hand grabs and end brackets for fastening to
abutting construction. Maximum deviation in the linear dimensions of railings, stairs and ladders,
from the approved dimensions, shall not exceed 12 mm.
9.11 Chequered plate
Chequered plates shall be fixed to supporting members by welding as specified in relevant drawings
or as directed by the Project Engineer and Executing Agency. The edges shall be made smooth
and no burrs or jagged ends shall be left. While splicing care should be taken so that there is
continuity in pattern between the two portions. Care should also be taken to avoid distortion of the
plate while welding of stiffening angles/vertical stiffening ribs.
9.12 Ash storage silo / intermediate hopper
Shape of the silo/intermediate hopper shall be circular in plan. Bottom hopper portion shall be of
conical shape and/or flat bottom type as specified in mechanical section.
For general requirements, fabrication and construction details, including design criteria, IS:9178
(Pt.I, II & III) shall be followed as general guidance.
Side walls shall be made of mild steel plates having horizontal and vertical stiffeners at regular
interval as per the design requirements. Stiffeners shall be provided on the external face. Joints
between the walls inside the silos should be continuously welded to ensure complete sealing.
However, for the stiffeners provided on the outer shell, intermittent welding may be adopted.
Bending of plates and rolled sections to the required shape for fabrication shall be done by plate
bending machine or cold bending process without resorting to heating, hammering, angle smithy
and black smithy process.
Poking hole and 10 mm thick striking plate shall be provided to facilitate ash flow. Poking holes
shall have circular m.s. pipe and cover cap as shown in the drawing.
9.12.1 Lining
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To cater for corrosion, abrasion or smoothness lining shall be provided in sloping/conical portion
as specified in mechanical section. Lining shall generally be in the form of stainless steel sheet of
3 mm thickness of grade SS 316 or 10 mm thick alloy C.I. liners of 300-350 BHN (min.).
9.12.2 Intermediate/buffer and storage silos hoppers
The hoppers shall be conical in shape with valley angle as 55 degrees and the details of hopper
specifications are covered elsewhere in these specifications.
9.13 Sampling, testing and quality control
9.13.1 General
a) The Concessionaire shall carry out all sampling and testing in accordance with the relevant
Indian Standards and/or International Standards and shall conduct such tests as called for by
the Project Engineer and Executing Agency. Where no specific testing procedure is mentioned,
the tests shall be carried out as per the prevalent accepted engineering practice to the directions
of the Project Engineer and Executing Agency. Tests shall be done in the field and at a
laboratory approved by the Project Engineer and the Concessionaire shall submit to the Project
Engineer and Executing Agency, the test results in triplicate within three days after completion
of a test. The Project Engineer and Executing Agency may, at his discretion, waive off some
of the stipulations given for small and unimportant operations.
b) Material / work found unsuitable for acceptance shall be removed and replaced by the
Concessionaire. The work shall be redone as per specification requirements and to the
c) Radiography and ultrasonic testing of welds shall be carried out by specialist agency only. In
case, the Concessionaire does not have the required expertise, he shall engage specialist agency
for this purpose.
An indicative program of Inspection and testing for raw materials, welds and dimensional
tolerances for fabrication & erection of steel structures are given in Annexure - B. The
Concessionaire shall draw-up a comprehensive program for executing the works based on this
indicative program.
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Annexure - B
Inspection, testing and quality check list
1 Inspection & testing
The Concessionaire shall carry out a comprehensive inspection and testing program of inspection
/ testing on the basis of details given below. The testing of all the materials supplied by the
Concessionaire shall be carried out by him. This is however, not intended to form a comprehensive
program as it is the Concessionaire’s responsibility to draw-up and carry out such a program duly
approved by the Project Engineer and Executing Agency. Such approval shall not relieve the
Concessionaire of the responsibility about the correctness and adequacy of workmanship, materials
etc.
1.1 Raw material inspection
1.1.1 Steel
i) Conformity with specifications
a) The conformity of the materials with the specification and the availability of the relevant
test certificates shall be checked. Carbon equivalent value shall also be made available.
b) Plates above 25 mm thickness shall be subjected to ultrasonic test as per ASTM A435 or
equivalent to check the presence of lamination.
ii) Physical conditions:
a) Steel shall not be pitted and should be free from scales and rust.
b) If the rolled sections and plates are bent or distorted, bend or distortion shall normally be
removed by cold treatment etc.
c) Straightening under hot stage shall be resorted only under specific permission from the
d) If any rolling defects, viz. lamination, cracks etc. are discovered in the steel during the
processing, it is to be rejected.
iii) Storage
a) Steel plates of different specifications shall be stacked separately.
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b) Steel of IS:2062 (different grades) and IS:8500 quality shall be given distinctive
identification mark.
c) Rolled sections shall be stacked profile-wise separately.

d) Steel sections shall be stacked over spacers supported on posts of about 50 cm. height
above ground. Passages and space between the stacks shall be sufficient for rigging
operations.
1.1.2 Electrodes
i) Electrodes for all welding shall be procured as envisaged in the welding procedure sheet
predetermined before actual welding operation starts/
ii) Electrodes shall be properly stored dry as required by the IS Code or by the manufacturer.
iii) Electrodes shall bear the ISI or equivalent Certification mark.
iv) The approval for all the consumables for welding shall be specifically obtained beforehand.
1.1.3 Nuts, bolts etc.
i) The quality of these shall be as per relevant IS codes.
ii) They shall be stored properly according to grade, diameter and length. However, special bolts
like HSFG shall be stored separately as per the relevant clause.
iii) Bolts of well known manufacturers are acceptable with manufacturer’s test certificates.
However, in case the Concessionaire is not able to produce the test certificate, the bolts can be
accepted only after satisfactory cold bend and flattening tests. For the purpose of these tests,
the inspecting officer should select at random 3 specimens each for cold bend and flattening
tests. For the purpose of these tests, the inspecting officer should select at random 3 specimens
each for cold bend and flattening tests out of each consignment of 1000 Nos. or less and instruct
the Concessionaire to carry out the tests in his presence. Cost of testing shall be borne by the
Concessionaire.
1.1.4 Paints/primers
i) The relevant IS or equivalent mark on sealed tins shall be checked.
ii) A few tins shall be opened at random to check the condition of the paint. Paint from old stock
and showing signs of solidification shall not be accepted.
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1.1.5 Cement
i) The quality of cement shall conform to relevant IS code.
ii) Cement is to be stored in a place of easy access for proper inspection and identification. It
should be placed in a weather tight building, so that dampness and loss due to other causes is
minimum.
1.2 Welding procedure qualification
Welding procedure shall be established as per ASME Section IX or equivalent Indian Standards.
Welding procedure, specifications shall be submitted by the Concessionaire for review and
approval of the Executing Agency. Typical welding procedure data sheet is given in Proforma A.P-
1.
1.3 Welders qualification test
Welders qualification test shall be as per ASTM Section IX or equivalent Indian Standards.
1.4 Inspection for tack assembly set up :
i) Bevel
ii) Gap
iii) Off-setting
iv) Shrinkage allowance
v) Fitment Sequence
vi) Principal overall size
1.5 Preheating:
Temperature control by Thermochalk or suitable equivalent method.
Inspection of main welds of principal components for columns, crane girders, framing beams,
trusses, etc.
I) Fillet welds for :
i) Check size
ii) Macrotech examination of production test coupons for main fillet weld.
iii) 100% visual examination
iv) 100% dye penetration test/magnetic particle test - Major welds (including welds subjected
to tension) like web to flange connection, splice plates, moment/shear connection.
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v) 10% All other areas.
II) Butt welds :
a) Columns, Beams etc.
i) 100% Visual examination
ii) 100% Dye penetration test after back gouging shall be carried out. Final weld shall
also be tested.
iii) Mechanical testing of production test coupons - Minimum one joint per column/built
up beam and crane grinder etc. The Project Engineer and Executing Agency may
reduce the frequency of this test, after getting consistently satisfactory results for initial
10 tests.
iv) 100% Radiography test on tension zone (bottom flange of the girder) welds and 10%
spot Radiography on compression zone for minimum 300 mm length (top flange of the
girder) welds of crane girder shall be carried out. Where Radiography test is not
possible, ultrasonic test shall be carried out after grinding the surface wherever
required with prior approval of the Project Engineer and Executing Agency.
v) All other butt welds and full penetration welds shall be subjected to 10% spot
Radiographic test and for the balance ultrasonic test. Wherever Radiography is not
possible, ultrasonic testing shall be carried out with prior approval of the Project
b) Dry ash silo :
i) Dye penetration test after back gouging and for all finished welds.
ii) 10% spot Radiography test on fabrication shop butt welds and 10% spot Radiography
test on site erected butt joints shall be carried out where access is available.
c) In case of failure of any weld in spot radiography the percentage for retesting shall be
doubled at that particular location.
1.6 Final inspection
i) Dimensional check as per fabrication check list detailed elsewhere.

ii) Marking for holes for fitments or connection and hole sizes.
iii) Erection mark
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iv) Painting
a) Dressing and surface preparation.
b) Final painting including dry film thickness (DFT) by using Elcometer or any other approved
method. In addition, the rate of application (coverage) as per manufacturer’s
recommendation shall be checked.
1.7 Inspection during fabrication and erection
a) All structural components/members shall be checked for dimensional tolerance during

fabrication and erection.
b) Tolerance on dimensions for fabrication of structures shall be according to IS:7215 and check
list given under table A-1 to A-5. In case of any conflict between the provisions of IS:7215
and those mentioned under the table, the stipulation of the latter shall govern.
c) Tolerance on dimensions for erection of steel structures shall be according to IS:12843.

Relevant portion of the same is given under Table A-6 for ready reference.
1.8 Welding tests on welds and weld defects
Mechanical testing of welds (destructive tests): Butt welds having one or more of thefollowing
defects are not acceptable.
i) Bend Test : No crack on root/face on being bent through 180 degree with
mandrel of 41 where t is the thickness of plate.
ii) Tensile Test : Weld strength not less than parent metal’s strength.
1.8.1 Radiographic examination
Sections of welds that are shown by Radiography to have any of the following type of imperfections
shall be judged unacceptable:
1) Any type of crack or zone of incomplete fusion or penetration.
2) Any elongated slag inclusion which has length greater than :
i) 6mm for t upto 20 mm

ii) 8mm for t from 20 mm to 32 mm
iii) ‘t’ = thickness of weld
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3) Any group of slag inclusion in line that have an aggregate length greater than ‘t’ in a length of
12t, except when distance between the successive imperfections exceed 6L where ‘L’ is length
of longest imperfection in group.
4) Rounded indications in excess of that specified by the acceptance standard given in Appendix
4 of ASME section VIII Div. 1.
1.8.2 Ultrasonic examination
The welded joints will be tested by suitable combination of Angle and Normal beam probe
techniques to ensure scanning of the entire cross-section of weldments.
Acceptance standard
All indications which produce a response greater than 20% of the reference level shall be
investigated to the extent that operator can determine the shape, identify and location of all such
reflectors and evaluate them in terms of the acceptance standards given in (a) and (b) below:
a) Discontinuities are unacceptable if the amplitude exceeds the reference level and
discontinuities have lengths which exceed.
i) 6 mm for‘t’ upto 20 mm inclusive
ii) 8 mm for‘t’ from 20 mm to 50 mm inclusive
iii) 20 mm for‘t’ over 50 mm
Where‘t’ is thickness of weld being examined. If a weld joins two members having different
thickness at the weld,‘t’ is thinner of these two thickness.
b) Where discontinuities are interpreted to be cracks, lack of fusion, or incomplete penetration,

they are unacceptable regardless of discontinuities or signal amplitude.
1.8.3 Visual examination:
Following defects are not allowed:
1. Unsatisfactory appearance
2. Incomplete weld
3. Molten metal flow
4. Pits
5. Surface crack, lack of penetration
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6. Insufficient length
7. Surface defects exceeding 5% of weld seam area
1.8.4 Dye penetration test:
All surfaces to be examined shall be free of:
a) Relevant linear indications
b) Four or more rounded defects in a line separated by 1.5mm or less (edge to edge) except where
the specification for the material establishes different requirements for acceptance so far as
defects are concerned.
Evaluation of indicators
i) Linear indications are those indications in which the length is more than 3 times the width.
Only indicators with major dimensions greater than 1.5 mm shall be considered relevant.
ii) Rounded indications or indications which are circular or elliptical with length less than 3 times
the width.
iii) Any questionable or doubtful indications shall be tested to verify whether or not actual defects
are present.
iv) Localised surface imperfections may occur from machining work surface conditions or an
incomplete bond between base metal & cladding may produce similar indications which are
relevant to the deletions of unacceptable discontinuities.
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Table:1 - Tolerable deviation from designed linear dimensions in mm in the parts processed for
fabrication
Deviation / tolerances in mm
S. 2.5m 4.5m 9m 15m
Characteristic 1.5m 1.5m to
No. to to to &
& Below 2.5m
4.5m 9.0m 15m above
1 2 3 4 5 6 7 8
1a Deviation in length and width of
part cut out by:
i) Manual gas cutting 2.5 3.0 3.5 4.0 4.5 5.0
ii)Gas cutting by 1.5 2.0 2.5 3.0 3.5 4.0
automatic and semi-
automatic machines
iii) Shear or saw cutting 1.5 2.0 2.5 3.0 3.5 4.0
iv) Parts machined by edge- 0.5 1.0 1.5 2.0 2.5 3.0
planning or milling machines
b Difference in diagonal lengths of
sheet parts:
i) For butt welding 4.0 4.0 4.0 5.0 6.0 6.0
ii) For lap welding 5.0 5.0 5.0 8.0 10.0 10.0
c Deviation in distances between
hole centres, formed as per:
i) Marking of extreme 2.0 2.0 2.5 3.0 3.5 4.0
ones
ii) marking of adjacent 1.5 1.5 1.5 1.5 1.5 1.5
ones
2 Deviation in the dimensions of
structural despatch members after
finishing:
a When assembled upon assembly 3.0 4.0 5.0 7.0 10.0 15.0
benches as per marking.
b When assembled in the jig and 2.0 2.0 3.0 5.0 7.0 10.0
other devices fastening with
fixtures.
c Dimensions (length and breadth) 0.5 1.0 1.5 2.0 2.5 3.0
between milled surface (after
finishing)
3 Distance between groups of
erection holes (in finished
members):
a Formed during machining of 3.0 4.0 5.0 7.0 10.0 15.0
separate parts installed when
assembling as per marking.
306
Deviation / tolerances in mm
S. 2.5m 4.5m 9m 15m
Characteristic 1.5m 1.5m to
No. to to to &
& Below 2.5m
4.5m 9.0m 15m above
1 2 3 4 5 6 7 8
b Formed during machining of 2.0 2.0 3.0 5.0 7.0 10.0
parts, installed when assembling
with the help of fixtures.
c Drilled with the help of templates 0.5 1.0 1.5 2.0 2.5 4.0
in finished members.
Fabrication Check List

Table 2 : Tolerable deviations of fabricated members from designed geometrical shape
Sl. No. Characteristic Deviation / Tolerance Remarks

1. Curvature of assembly Parts
a) Gap between a sheet and a steel rule face 1.5 mm
over 1 m length
b) Gap between a taut string and vertex face of 0.001 L, L-length of
an angle flange or web of channel and joist. but not greater member
than 10 mm.
2. Deviation of edge line steel sheet parts from
theoretical profile:
a) During butt and toe welding 2 mm
b) During lap welding 5 mm
3. Deviation of radius of the bend:
a) Clearance between template and the surface 2 mm Template
of rolled sheet flange or face of cold bend length
profile. (1.5m along
the curve)
b) -do- for hot bend profile 3 mm -do
c) Ellipticity (difference of diameters) in space 0.005D D-diameter of
sheet structures. circumference
d) -do- in erection joints 0.003D -do-
4. Deformation of dispatch members:
a) Inclination of flanges with the web:
i) at junction 0.005b b-width of
flange
ii) at other places 0.01b -do-
b) Transverse bending of flanges:
i) at junction with members 0.005b b-width of
flange
ii) at other places 0.01b -do-
307
Sl. No. Characteristic Deviation / Tolerance Remarks
c) Warping of the web 0.003h h-depth of the
member
d) Sag of member L/750 but not more than L-length of the
15 mm member
5. Other deviations:
a) Shifting of axes of riveting/ bolting lines for 3.0 mm
lattice structures from theoretical eccentricity.
b) Inclination of the milled surface from 1/1500
designed position.
Fabrication Check List

Table 3: Acceptance deviations in as fabricated steel structures
S. No. Characteristic Deviation / Tolerance
1. Columns
a) Deviation in length ‘L’ measured distance from bottom
surface of the column footings, to the group of holes for
‘trusses’, fasteners, collar beams, purlins and other elements
to be connected to column.
When L is under 10 m  10 mm
When L is over 10 m  15 mm
b) Deviation in distance ‘L’ from bottom surface of the
column footing to the top of crane bracket.
When L is over 10 m  10 mm
c) Deviation in distance from bearing surface of the bracket  1 mm
to the first fastener of the element to be connected to column.
d) Deviation in distance between any group of holes for  2 mm
connection of bracings to columns.
e) Sag of column element (curvature) 1/1000 of length element but not
more than 15 mm.
f) Difference in web depth of column
i) At splice joint  2 mm
ii) At any other location  10 mm
g) Deviation in distance from supporting surface of milled  3 mm
end of the dispatched element of column to the clear or
heating plate or column to the cleat or seating plate for
fastening of collar beams, purlins, girders etc. (Fish plates,
brackets).
2. Trusses
a) Deviation in span ‘L’ of the truss between end erection
holes in gussets of supporting units or between external
308
S. No. Characteristic Deviation / Tolerance
planes of supporting gussets or angles when trusses are
resting on brackets or supports:
When L is over 25 m 1/2500 but not more than
10 mm
b) Deviation in distance between the centres of holes or  3 mm
webs of angles for fastening bracing, purlins, monitors, etc.
c) Deviation in distance between the first row of erection more than 15 mm.
holes and the
d) Distance between holes for fasteners to top and bottom  3 mm
chords of trusses on supports.
e) Sag of separate elements between node points. 1/1500 of length of element but
not more than 10 mm.
3. Beams
a) Deviation in span L of beams between bend erection
holes, outer surfaces of end plates:
When L is over 25 m  1/2500 length but not more than
15 mm
b) Deviation in the height of beam as measured from the  3 mm
bearing surface to the top of upper flange
c) Deviation in distance between the group of holes for  3 mm
fastening of purlins, monitors, bracings, bracing grids etc.
d) Sag (curvature) of the girder despatch member 1/1000 length but not more than
15 mm
4. Elements of framework Bracings, purlins etc.
a) Deviation in distance between end erection holes,  3 mm
determining the span of element.
b) Sag of despatch members 1/1000 length but not more than
15 mm
c) Deviation in distance between the groups of erection  3 mm
holes of the element
d) Gratings, Stair, Railings, ladders, etc.  12 mm
5. Shop assembly (before for erection) Despatch
a) Columns weighing more than 20 T i) Every first and further every
tenth set of identical structure to
be put for control assembly.
b) Roof trusses of 30 m or more span
c) Crane girders with span more than18 m
d) Bunkers i) Number of erection bolts shall
be atleast 30% of the total No. of
holes.
309
Fabrication check list
Table 4: Acceptable deviation in holes or bolts
S. Tolerance No. of
Characteristic Deviation
No. deviation in each group
1. a) Deviation of dia of holes for rivet

and bolts:
Upto 16 mm  1 mm No limit
Over 16 mm  1.5 mm
b) Deviation of dia of turned and
fitted bolts:
Nominal dia of bolts and holes Upper limit: + 0.125 mm
Lower limit: 0.00 No limit
2. Ovalness (difference between the
greatest and lesser dia)
Upto 16 mm hole dia + 1 mm No limit
Upto 16 mm hole dia + 1.5 mm
3. Deformity in size greater than 1.5 Not permitted
mm and cracks in the edge of holes.
4. Misalignment of holes in separate
plates in the joints:
i) Upto 1 mm Upto 50%
ii) From 1 to 1.5 mm Upto 10%
Note: In holes shall be removed, the depth and width of countersunk hole shall not deviate from the standard
by more than 1.5 mm.
Fabrication check list

Table 5: Permissible fabrication deviation of structural steel
Type of structures Value of deviation
S. No. Name of deviations
and constructions (Tolerance)
1. Column Assembly fits
a) Base plate and column 0.1 mm
b) Frame Joints 2.0 mm
c) Web and flange 1.5 mm
d) Web & stiffeners 1.5 mm
e) Flange & stiffeners Intermediate 1.5 mm
stiffeners& Bearing stiffeners
f) Cap plate & column 0.1 mm
g) Crane girder seat 0.1 mm
h) Beam brackets 2.0 mm
2. Beams (c), (d), (e) of S.No. 1 above 1.5 mm
310
Type of structures Value of deviation
S. No. Name of deviations
and constructions (Tolerance)
3. Crane Girders (c), (d), (e) of S.No. 1 above and knife edge 0.1 mm
supports
4. Silos & hoppers a) Ring beam and wall 1.5 mm
b) Stiffeners and walls 1.5 mm
c) Stiffeners and ring beams 1.5 mm
d) Deflection of straight section of 1/1500 of span but nore
compression cord from the plane of truss, more than 10mm
collar beam or girder.
5. Purlin Deviation in distance between purlins. 5 mm
Erection check list

Table 6: Maximum permissible tolerances in steel structures
S. No. Description Tolerance
1. Erected steel columns:
i) Deviation of column axis at foundation top level with respect
to true axis:
a) in longitudinal direction  5 mm
b) in lateral direction  5 mm
ii) Deviation in the level of bearing surface of columns at  5 mm
foundation top with respect to true level
iii) Out of plumbness (verticality) of column axis from true
vertical axis as measured at column top:
a) For columns without any special requirements:
1) upto and including 30 m height  H or  25 mm
1000 whichever is less
2) over 30 m height  H or  35 mm
b) For column with special requirements like cranes or such
similar requirements:
1) upto and including 30 m height  H or  25 mm
2) over 30 m height  H or  25 mm
iv) Deviation in straightness in longitudinal and transverse of  H or  10 mm
column at any point along the height. 1500 whichever is less
v) Difference in the erected positions of adjacent pairs of  5 mm
columns along length or across width of building prior to
connecting trusses/beams with respect to true distance.
vi) Deviation in any bearing or seating level with respect to  5 mm
true level.
311
vii) Deviation in difference in bearing levels of a member on  5 mm
adjacent pair of columns both across and along the building.
Notes:
1. Tolerance specified under iii (a) and iii (b) should be read in conjunction with iv and v.
2. ‘H’ is the column height in mm.
Table 6 (Contd.)
2. Erected steel trusses
I) Shift, at the centre of span of top chord member with  1 of height of
respect to vertical plane passing through the centre of 250 truss in mm at centre of
bottom chord. span or  15 mm whichever is
less.
ii) Lateral shift of top chord of truss at the centre of span  1 of span of
from the vertical plane passing through the centre of 1500 truss in mm or  10 mm
supports of the truss. whichever is less.
iii) Lateral shift in location of truss from its true axis in plan.  10 mm
iv) Lateral shift in location of purlin from true position.  5 mm
v) Deviation of difference of bearing levels of trusses from  1 of span of
the true difference. 1200 truss in mm or  20 mm
whichever is less.
3. Erected Crane Girder and Rails
i) Shift in the centre line of crane rail with respect to centre (Web thk in mm) + 2 mm
line of web crane girder. 2
ii) Shift in plan of alignment of crane rail with respect to  5 mm
true axis of crane rail at any point.
iii) Deviation in crane track gauge with respect to the
gauge:
a) For track gauge upto and including 15 mm  5 mm
b) For track gauge more than15 mm  (5 + 0.25(S-15)) mm subject to
a maximum of  10 mm, where
S in meters is true track gauge.
iv) Deviation in the crane rail level at any point from true  10 mm
level
v) Difference in levels between crane track rails at:
a) Supports of crane girders 15 mm
b) Mid span of crane girders 20 mm
vi) Relative shift of crane rail surface at a joint plan and 2 mm subject to grinding of
elevation. surfaces for smooth transition.
312
Proforma - A.P.1
Typical welding procedure data sheet
Concessionaire...........................................................Address...........................................................
Quality of weld....................................................Specification.........................................................
Material Specification...........................................Thickness.......................................Batch/
Cast No........................................................Joint preparation (Fig)...................................................
Gap............................................................Location of Specimens....................................................
Whether condition..................................................Type of Day.......................................................
Wind break used................................................................................................................................
Electrode Group No.................................Make..................Specimen...............................................
Pre and Post Heating..........................................................................................................................
Welding position................................................................................................................................
Size of reinforcement................................................Whether removed............................................
Welding Sequence.............................................................................................................................
Backing strip used............................................Type..........................................................................
Welding process.................................................................................................................................
Current conditions Polarity................................................................................................................
Size of electrode.................................................................................................................................
Amperage and Voltage......................................................................................................................
Number of Electrodes used per run...................................................................................................
Cleaning method................................................................................................................................
313
Remarks.............................................................................................................................................
Welding Engineer
Executing Agency
Signature
(Inspecting Authority)
For and behalf of Concessionaire
Date:___________________
314
Sub section - C10
Technical specification for glass and glazing
315
Sub section - C10
Technical specification for glass and glazing
Contents
10.1 Scope ............................................................................................................................................. 317

10.2 Installation..................................................................................................................................... 317
10.3 Glazing, setting and finish ............................................................................................................ 318
10.5 IS codes ......................................................................................................................................... 318
316
Sub section - C10: Technical specification for glass and glazing
10.1 Scope
The work in general shall consist of supplying and fixing all glass and glazing including all clips,
putty, mastic cement, etc. wherever required.
10.2 Installation
10.2.1 General
The Concessionaire shall supply and install all glass and glazing as required for various doors,
windows, sashes, ventilators and fixed louvers, miscellaneous glazing and partitions, as approved
by the Executing Agency, having very high optical clarity, brighter appearance, uniform thickness,
consistent product quality manufactured out of molten glass coming out of the furnace floats on
molten tin, thus being formed into float glass. The glass shall be delivered to site in containers with
the maker's name, guarantee, type of glass and thickness, or weight of glass attached to the outside
of the containers. Glass cut to size shall be straight and free from chips, spalls or any other damage
on any cut edge.
10.2.2 Materials
(a) Clear glass shall be flat drawn sheet glass and shall be atleast 4 mm thick conforming to
IS:2835. Sheet glass for doors shall be minimum 5.5 mm thick.
(b) Wired glass shall be thick rolled glass with centrally embedded 24G wire mesh of Georgian
type. This may be of clear or coloured glass as shown in drawings and shall conform to
IS:5437.
(c) Composite double glazing shall be made of double glazing of two 6 mm thick sheet glass
either both sheets of tinted glass or one glass tinted & other plain or both sheets of plain sheet
glass. Both the glasses shall be separated by an air gap of 12 mm. The trapped air shall be
kept dry by means of suitable desiccant. The sealing shall be under strict quality control. The
composite glazing shall be procured as finished product from reputed manufactures. Toughen
glass conforming to IS:2553 shall be used.
(d) Obscure glass shall have a cast surface on one side.
(e) Coloured and figured glass shall be as per the approved sample.
(f) In general, the putty shall conform to IS:410 latest edition and be of best quality from an
approved manufacturer. It shall be brought to site in the manufacturer's original packing.
Quick setting putty shall be used for windows and sashes except when glare reducing glass
is used where it shall be of non-setting type.
317
(g) Neoprene gaskets with snap-fit glazing shall be fixed as per manufacturer's instructions and
shall fit firmly against the glass to give a leak proof installation.
10.3 Glazing, setting and finish
All glazing clips, bolts, nuts, putty, mastic, cement, etc., shall be supplied by the Concessionaire.
All glass shall be thoroughly cleaned before placing in position. Each glass pane shall be held in
place by special glazing clips of an approved type. Four glazing clips shall be provided per glass
pane, except for large panes where six or more clips shall be used as instructed by the Project
Engineer and Executing Agency. All holes that may be necessary for holding the clips, glazing
beads and all other attachments shall be drilled by the Concessionaire.
Glass panes shall be set without springing, and shall be bedded in putty and back puttied, except
where mouldings or gaskets are specified. Putty, mastic cement etc., shall be smoothly finished to
a true even line. Obscure and figured glass shall be set with smooth side out.
After completion of glazing work, the Concessionaire shall remove all dirt, stains, putty, etc., clean
the glass panes and leave the work in perfectly acceptable condition. All broken, cracked or
damaged glass shall be replaced by new at the Concessionaire's own cost.
(a) All installations shall be free from cracked, broken or damaged glass. Edges of large panes
of thicker glass and heat absorbing glass shall be inspected carefully for chipped, cracked or
unground edges.
(b) Glazing shall be carefully done to avoid direct contact with metal frames.
(c) All glass shall be embedded in mastic or fixed by neoprene gaskets to give a leak-proof
installation.
(d) At completion the panes shall be free from dirt, stains, excess putty, etc., to the complete
10.5 IS codes
Some of the important applicable Indian Codes for this section are listed below. Latest editions of
these codes shall be followed:
IS:3548 Code of Practice for glazing in building.

IS:1083 Code of practice for fixing and glazing metal doors, windows and
ventilators.
IS:419 Putty for use on window frames.
318
Sub section - C11
Technical specification for MS doors, windows, ventilators, louvers, etc.
319
Sub section - C11
Technical specification for MS doors, windows, ventilators, louvers, etc.
Contents
11.1 Scope ............................................................................................................................................. 321

11.2 Installation..................................................................................................................................... 321
11.4 Information to be submitted .......................................................................................................... 326
11.5 IS codes ......................................................................................................................................... 326
320
Sub section - C11: Technical specification for MS doors, windows, ventilators, louvers, etc
11.1 Scope
The work in general shall consist of supplying, erecting and installing of all MS doors, windows,
ventilators, louvres, glazed partitions etc. as required with all materials, complete excluding supply
of glass and glazing. Supplying and/or fixing of all door and window accessories and hardware are
also included in the scope.
11.2 Installation
11.2.1 Materials
Steel sections used for fabrication of doors, windows, etc. shall be standard rolled steel sections
specified in IS:1038 and IS:1361. Mild Steel sheets for frames, shutters, louver blades, etc. shall be
of the gauge mentioned in this specification.
Hardwares and fixtures of the best quality from approved manufacturers only shall be used. The
Concessionaire shall specifically state the particular manufacturer’s materials, proposes to use. All
hardware and fixtures shall be able to withstand repeated use. Door closers shall conform to IS:3564
latest edition and shall be suitable for doors weighing 61-80 kg unless otherwise stated. Each closer
shall be guaranteed against manufacturing defect for one year and any defect found within this
period shall be rectified or the closer replaced free of charge. Concealed doors closers shall be
either floor mounted or transform mounted suitable for installation with metal doors. They shall
conform to the performance requirements and endurance test stated in Appendix A of IS 3564
(latest edition).
Aluminium sections for fabrication of doors, windows, partitions etc. shall be extruded section
conforming to IS:1948 and 1949 or as manufactured by Indian Aluminium Company Ltd. or
approved equivalent. The alloy used shall conform to IS designation HE-9-WP of IS:733. Heavy
duty double acting floor springs where specified shall conform to IS:6315, shall be suitable for door
shutters weighing upto 125 kg. shall be hydraulically regulated, shall be constructed of cast brass
casting cover and shoe, gun metal piston player and all other parts of mild steel.
The Concessionaire shall submit samples of each type of hardware to the Project Engineer and
Executing Agency. The approved samples shall be retained by the Project Engineer and Executing
Agency for comparison of the bulk supply. The samples shall be returned to the Concessionaire
towards the end for incorporation in the job.
The mastic for caulking shall be of best quality from a manufacturer approved by the Project
Engineer and Executing Agency. In general the mastic for fixing of metal frames shall be as per
IS:1081 latest edition and/or as approved by the Project Engineer and Executing Agency.
11.2.2 Fabrication
321
 Steel doors, windows, ventilators, louvers, etc.
(a) Door frames :
Frames shall be fabricated from 16 G sheets. They shall be mortised, reinforced, drilled and tapped
for hinges, lock and bolt strikes. Where necessary, frames shall be reinforced for door closers.
Welded construction with mitred corners shall be used. Rubber door silencers shall be furnished
and for the striking jamb, Loose ‘T’ masonry anchors shall be provided. Frames shall finish flush
with the floor and adjustable floor anchors shall be supplied. Frames shall be brought to site with
the floor ties/weather bars installed in place.
(b) Double plate flush door shutter
Door shutters shall be 45 mm thick completely flush design and shall comprise of two outer sheets
of 18G steel sheets rigidly connected and reinforced inside with continuous vertical 20 G stiffeners,
spot welded in position at not more than 150mm centres. Both edges of doors shall be joined and
reinforced to full height by steel channels placed immediately inside and welded to the door faces.
The tops and bottoms of doors shall be reinforced horizontally by steel channels running to the full
width of the door. Doors shall have proper level on lock stiles and rails to operate without bending
and shall be reinforced at the corners to prevent sagging or twisting. Pairs of double doors shall
have meeting stile edges bevelled or rebated. Wherever required the doors shall be sound deadened
by filling the inside voids with mineral wool or other suitable approved materials.
Door shall be mortised, reinforced, drilled and tapped in the shop for hinges, locks and bolts. They
shall also be reinforced for closers, push plates and other surface hardware where necessary.
Any drilling and tapping required on the surface shall be done at site. Wherever required provision
shall be made for fixing glazing, vision panels, louvers, etc. Glazing mouldings shall be of 18 g
steel as directed by the Project Engineer and Executing Agency. Louvre blades shall be V or Z
shaped and made out of 16 G sheets.
(c) Single sheet door shutters
Single sheet doors shall be made from best quality 18 G mild steel sheets and shall present a flush
surface on the outside. The inside shall be stiffened with a semitubular edge and central stiffening
rail which shall support the lock and other furniture. The frames shall be made from best quality
16 G mild steel sheets.
Wherever required provision for fixing glass panels, louvers, etc. shall be made.
Fabrication shall be as specified in 2.02.01 (b) “Double Flush Door Shutters”.
(d) Sliding doors
322
Sliding doors shall be either double plate or single plate construction as required and made out of
18 gauge steel sheets with adequate stiffeners.
The Concessionaire shall specify the weight of the door in his shop drawing and submit the
manufacturer’s catalogue of the sliding gear he proposes to use. The Concessionaire shall make
provisions where necessary for openings in the door for monorail beams. Doors shall close
positively to exclude rain water from seeping in. Sliding doors shall withstand specified wind loads
without buckling or jamming. The door shall slide freely under all ambient conditions.
(e) Steel windows, sashes, ventilators, etc.
These shall conform in all respects to IS:1038 and IS:1361 latest editions. The details as called for
in the above codes shall be applicable for coupling mullions, transoms, weather bars, pivot
arrangements for ventilators, etc.
All welds shall be flush butt welded to form a solid fused joint, so that all frames are square and
flat.
Where composite unit openings are envisaged the individual windows units shall be joined together
with requisite transom and mullions. All windows shall be outside glazed fixed with putty or metal
glazing beads. Where aluminium glazing beads are specified they shall be extruded aluminium
channel 9.5 mm x 9.5 mm x 1.6 mm (Indal section No.2209) aluminium beads shall be given one
coat of zinc chromate primer before fixing to windows.
 Welding
The joints for steel doors, windows, ventilators, etc. shall be electrically flash butt welded joint at
all corners and junctions to form a solid fuses right angle joint.
 Fabrication of aluminium doors, windows, frames, etc.
Extruded sections shall have a minimum 3 mm wall thickness. All sections shall be approved by
the Project Engineer and Executing Agency before fabrication is taken up. Doors, windows,
frames, mullions, transformers etc. shall be anodized in bath of sulphuric acid to provide a clear
coating of minimum 10 micro-meter. The anodized materials shall then be sealed by immersing in
boiling water for 15 minutes. A protective transparent coating shall be applied to the sections
before shipment from the factory.
Fabrication drawings shall be submitted by the Concessionaire which shall also include the weights
of the materials used and got approved from the Project Engineer and Executing Agency.
11.2.3 Shop coat of paint

The shop paint for steel doors, windows, etc. shall be best red oxide, zinc chromate primer paint
from approved manufacturer conforming to IS:2074, latest edition. All surfaces shall be thoroughly
323
cleaned of rust, grease, loose mill scales, etc. and given one coat of shop paint. Portions like
mullions transoms, etc. which will be inaccessible after assembly of units shall be given an extra
coat of paint before assembly.
11.2.4 Handling and storage of fabricated material
All metal doors, windows, etc. shall be packed and crated properly before despatch to ensure that
there will be no damage to the fabricated materials. Loading into wagons and trucks shall be done
with all care to ensure safe arrival of materials at site in an undamaged condition. All metal doors,
windows, etc. shall be stored under cover and handled in a way to prevent damage or distortion.
Special care shall be taken to prevent staining of aluminium products by rust, motor etc.
11.2.5 Assembly and erection at site
In general the fixing of steel doors, windows, ventilators, louvres, etc. shall conform to IS:1081
latest edition. The Concessionaire shall assemble and install all steel doors, windows, sashes, fixed
metal louvres, etc. including transoms and mullions for composite units in respective places
keeping proper lines and levels, and in an approved workman like manner to give a trouble free
and leak proof installation. If required by the Project Engineer and Executing Agency, the
installation shall be carried out under the supervision of the manufacturer’s staff.
After installation of steel doors, windows, etc., all abrasions to the shop-coat of paint shall be
retouched and made good with the same quality of paint.
All coupling mullions, transoms, frames, etc. in contact with adjacent steel and other members shall
be well bedded in mastic. The Concessionaire shall bring to site the mastic cement in original sealed
containers of the manufacturer and shall apply it as per the manufacturer’s instructions.
Floor, shutters, partitions, hardware fixtures, etc. shall be fixed only after the major equipment has
been installed in the rooms.
Wherever required, nylon cords of approved quality shall be supplied along with pivoted sashes.
These shall be adequate length to terminate one metre from the floor. Loose ends of cords shall
have a metal or plastic pull as approved by the Project Engineer and Executing Agency.
11.3.1 For fabricated items
(a) Overall dimensions shall be within ± 0.5mm of the size.
(b) Mullions, transoms, etc. shall be in one length and permissible deviations from straightness
shall be limited to plus minus 0.5 mm from the axis of the member.
324
(c) Door and window shutters shall operate without jamming. The clearance at head and jamb
for door shutters shall not exceed 1.5mm. For double leafs the gap at the meeting stiles shall
not be more than 1.5mm.
(d) Door leafs shall be undercut wherever required.
(e) Doors, windows, frames, etc. shall be on a true plane, free from warp or buckles.
(f) All welds shall be dressed flush on exposed and contact surfaces.
(g) Correctness of hardware and smoothness of operation of all shop installed hardware and
fixture.
(h) Provisions for hardware and fixtures to be installed at site.
(i) Glazing beads shall be cut with mitred corners.
(j) Shop coats shall be properly applied.
(k) Exposed aluminium surface shall be free from scratches, stains and discolouration. Anodized
surfaces shall present a uniform and pleasing look.
11.3.2 For installed items
(a) Installation shall be at the correct location, elevation and in general on a true vertical plane.
(b) All frames of external walls shall be mastic caulked to prevent leakage through the joint
between frames and masonry.
(c) All openable sections shall operate smoothly without jamming.
(d) Locks, fasteners, etc. shall engaged positively. Keys shall be non-interchangeable.
(e) Cutting to concrete or masonry shall be made good and all abrasions to shop paint shall be
touched up with a paint of the same quality as the shop paint.
(f) Aluminium doors, windows etc. shall be free scratches, stains or discolouration.
(g) It shall be the responsibility of the Concessionaire to see that the material is protected from
mortar, paint, plaster, terrazzo framing members.
325
11.4 Information to be submitted
Before starting fabrication of any metal doors, windows, etc. the Concessionaire shall submit
detailed fabrication drawings to the Project Engineer and Executing Agency for approval. The
fabrications shall be started only after approval of the drawings.
11.5 IS codes
The important IS codes to be followed are listed below:
IS:1083 Steel doors, windows and ventilators.

IS:1361 Steel windows for industrial buildings.
IS:1451 Steel door frames.
326
Sub section - C12
Technical specification for rolling steel shutters / grills
327
Sub section - C12
Technical specification for rolling steel shutters / grills
Contents
12.1 Scope ............................................................................................................................................. 329

12.2 Installation..................................................................................................................................... 329
12.4 IS codes ......................................................................................................................................... 331
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Sub section - C12: Technical specification for rolling steel shutters/grills
12.1 Scope
This specification covers the design, supply of materials, fabrication, delivery and erection of
rolling shutters grills with motor drives and/or manual operation during all accessories as
hereinafter specified. All electrical work shall be in strict accordance with the latest Indian
Electricity Rules.
12.2 Installation
12.2.1 Components
a) States for rolling shutters shall be made from tested bright, cold rolled, annealed M.S. strips,
not less than 0.9 mm thick for shutters upto 3.5 m wide and not less than 1.24 mm thick for
shutters 3.5 m wide and above, machine rolled at 75 mm rolling centres, interlocking with each
other. The profile will be such as to prevent excessive deflection under specified wind load.
b) Rolling grills shall be constructed out of 6 mm dia. rods at 35 mm centres running horizontally
flexibly connected with vertical links spa ed not more than 200 mm centres. Alternatively,
rolling grills shall be made from perforated slats of approved design, reinforced with 6 mm dia
rods.
c) End locks shall be heavy type M.C.I./C.I. and shall be provided at each end of alternate slats.
d) Bottom bars shall be finished with two angles not less than 6 mm thick for external shutters.
When shown on drawings, a flexible weather strip shall be applied to make tight contact with
the floor.
e) Guide shall be of such depth as to retain the shutter under a wind pressure of 150 kg/sq.m. The
minimum thickness of guide shall be 126.
f) Shafts shall be of steel pipes of sufficient size to carry the torsional load with a maximum
deflection of 1/360th of span. Grease packed ball bearings or bushings shall be provided for
smooth trouble, free operation.
g) Hoods shall be formed of not less than 20 gauge steel, suitably reinforced to prevent sag.
h) Locks shall be side belt and hasp or cylinder lock operable from one or both sides. Provision
for to securing hand chain with pad-lock, provision for removable handle for hand cranks etc.
shall be made as desired by the Project Engineer and Executing Agency.
i) Power unit shall be suitable for 3 phase, 50 cycle, 400 volt A.C. Power supply and shall be
either floor or wall mounted unit. The motors shall be of sufficient capacity to move the shutter
in either direction at a speed of 0.3 metres per second. In addition to the gear motor, each
standard power unit shall include a magnetic brake, reversing starter with built-in overload
protection, a geared limit switch and one push button station located inside the building unless
otherwise stated. It is desirable that the button bar or motor operated doors shall be provided
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with a sensitive edge, electrically connected to stop the travel of the door on meeting an
obstruction.
j) Operating chains shall be of tested quality, heavily galvanized and with all ends rounded to
assure smooth operation and hand protection.
k) Reduction gears shall be of high strength grey cast iron, machine moulded from machine cut
patterns.
12.2.2 Manually operated shutters/grills
Manually operated shutters shall be easily operable by one person. The speed of operation shall be
about 0.3 metres per second.
In general, manually operated shutters shall be push-pull type for opening upto 9 sq. metre in area.
Larger shutters shall be either chain and gear operated or crank and gear operated. The crank handle
shall be removable. All shutters shall be lockable from one or both sides as desired by the Project
12.2.3 Power operated shutters/grill
These shall be operable from a push button station conveniently located beside the door or as shown
on drawings. One emergency hand chain-crank operation shall also be provided for use in case of
failure of the electrical system.
12.2.4 Shop coat
Shutters shall be painted with one coat of red lead or zinc chromate primer. Where specified, doors
shall be galvanized and subsequently painted with one coat of zinc chromate for adhesion of field
coat.
12.3.1 Shop inspection
After completion the manufacture of different components of the rolling shutter, an arrangement
for shop inspection by the Project Engineer and Executing Agency shall be made to check the
conformity with approved shop drawings.
12.3.2 Field inspection
After installing the shutters, the Concessionaire shall test the performance of the shutter in the
presence of the Project Engineer and Executing Agency. The doors shall be smoothly operable
under all ambient conditions. All control and locking devices shall give fault- free performance.
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12.3.3 Guarantee
The Concessionaire shall give one year’s guarantee for the successful operation of the shutters.
12.4 IS codes
IS:6248 Metal rolling shutters and rolling grills.
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Section - WS1
Technical specifications for laying of pipes and fittings / specials
332
Section - WS1
Technical specifications for laying of pipes and fittings / specials
Contents
1. Scope ................................................................................................................................................. 334

2. Applicable codes ............................................................................................................................... 334
3. Carting & handling ........................................................................................................................... 335
4. Storage .............................................................................................................................................. 335
5. Laying ............................................................................................................................................... 336
6. Measurement ..................................................................................................................................... 343
7. Notes ................................................................................................................................................. 344
8. Data Sheet – A .................................................................................................................................. 344
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Section - WS1: Technical specifications for laying of pipes and fittings / specials
1. Scope
The work shall include providing of materials, all necessary plant and equipment, providing
adequate engineering supervision and technical personnel, skilled and unskilled labour, etc. as
required to carry out the entire work as indicated on the drawings and/or described herein
subsequently and/or as directed by the Project Engineer and Executing Agency. The Concessionaire
shall carry out all works meant within the intent of this specification even if not explicitly
mentioned herein.
All works shall be executed as per specification and relevant IS code and to the satisfaction of the
2. Applicable codes
The laying of pipes and fittings/specials shall comply with all currently applicable statutes,
regulations, standards and codes. In particular, the following standards, unless otherwise specified
herein, shall be referred. In all cases, the latest revision of the standards/codes shall be referred to.
In the event of conflict between any of these Specifications and the Codes referred, such
specifications shall be defined (method statement of execution of works), prepared by the
Concessionaire and submitted to the Project Engineer for approval. The decision of Project
Engineer in such case shall be final and binding on the Concessionaire.
Any approval, instructions, permissions, checking, review, etc. whatsoever by the Project Engineer
and Executing Agency, shall not relieve the Concessionaire of his responsibility and obligation
regarding adequacy, correctness, completeness, timely completion, safety, strength, quality &
workmanship etc.
positions of all work and establish the reduced levels (RLs) at these locations, based on two
reference grid lines and one bench mark which will be furnished by the Executing Agency. If need
be the Executing Agency reserves the right to have the Concessionaire re-verify the coordinates at
no cost to Executing Agency. The Concessionaire has to provide at site, all the required survey
instruments, along with qualified surveyors, to the satisfaction of the Project Engineer and
Executing Agency so that the work can be carried out accurately and according to the specifications
and drawings.
2.1 Codes of practice
All applicable standards, specifications, etc. and codes of practice shall be the latest editions,
including all applicable official amendments and revisions. A complete set of all these documents
shall generally be available at site, with the Concessionaire.
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All work shall be carried out as per the stipulations contained in various sections of these
specifications and the latest Indian Standards, Act, Codes and best practices.
In case of conflict between the stipulations contained in various sections of these specifications and
stipulations of Indian Standard Codes, etc. the requirements of stipulations contained in various
sections of these specifications shall prevail over that of Indian Standards, Codes, etc.
Concessionaire is responsible to notify Executing Agency in writing well in advance of such
conflicts prior to execution of the work.
Some of the applicable Indian Standards, Codes are referred to herein below:
(a) IS.783 - Code of practice for laying of concrete pipes

(b) I.S. 3114 - Code of practice for laying of cast iron pipes
(c) I.S. 3764 - Excavation work - code of safety
(d) I.S. 5822 - Code of practice for laying of electrically welded steel pipes for
water supply
(e) I.S. 6530 - Code of practice for laying of asbestos cement pressure pipes
(f) I.S. 1726 - Specifications for Cast Iron Manhole covers & frames
(g) I.S. 5455 - Specifications for C.I. steps for manholes.
(h) I.S.4111(Part -1) - Code of practice for ancillary structures in sewerage system
(manholes)
3. Carting & handling
Pipes and fittings/specials shall be transported to all the work sites at places along the alignment of
pipe line as directed by Project Engineer and Executing Agency. Concessionaire shall be
responsible for the safety of pipes and fittings/specials in transit, loading/unloading storage etc.
Every care shall be exercised in handling pipes and fittings/specials to avoid possible damage.
While unloading, the pipes and fittings/specials shall not be dropped down from the truck on to any
hard surfaces. They should be unloaded on timber skids with steadying ropes or by any other
approved means. Padding shall be provided between coated pipes, fittings/ specials and timber
skids to avoid damage to the coating. Suitable gaps between pipes/stacks of pipe should be left at
intervals in order to permit free access from one side to the other. In case of spigot & socket pipes
care should be taken regarding orientation of pipes while unloading. As far as possible pipes shall
be unloaded on one side of the trench only. The pipes shall be checked for any visible damage (such
as broken edges, cracking & spalling of pipe etc.) while unloading and shall be sorted out for
replacement. Any pipe which shows any damage to preclude it from being used shall be discarded.
Dragging of pipes and fittings/specials along concrete and similar pavement with hard surfaces
shall be prohibited.
4. Storage
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4.1 Each stack of pipes shall contain only pipes of same class and size, with consignment or batch
number marked on it with particulars of suppliers wherever possible. Storage shall be done on firm
level and clean ground and wedges shall be provided at the bottom layer to keep the stack stable.
The stack shall be in pyramid shape or the pipes laid lengthwise and crosswise in alternate layers.
The pyramid stack shall be made for smaller diameter pipes for conserving space in storing them.
The height of the stack shall not exceed 1.5 m. Also necessary security arrangements should be
provided to avoid these till the pipes are finally used.
4.2 Fittings/specials shall be stacked under cover and separated from pipes and with suitable security
measures.
4.3 Rubber rings shall be stored in a clean & cool store away from windows, boiler, electrical
equipment and petrol, oils or other chemicals. Particularly in the field where the rubber rings are
being used it is desirable that they do not be left out on the ground in the sun or overnight under
heavy frost or snow conditions.
5. Laying
5.1 General
The Concessionaire shall visit the site before tendering and get himself acquainted with site
conditions and the regulations regarding the laying of pipes in congested areas, heavy traffic areas
etc.
5.2 Excavation
Before excavating the trench the alignment of pipeline shall be approved by Project Engineer and
Executing Agency. The excavation of trenches and pits for manholes/chambers shall be carried out
in accordance with the specifications contained herein below and shall be done in such a manner
that IT DOES NOT GET FAR AHEAD OF THE LAYING OPERATION as approved by
Executing Agency.
After excavation of trenches, pipes shall not be lowered in position unless the dimensions of
trenches and bedding work at the bottom of the trenches are-approved and measured by Project
Engineer and Executing Agency. Pipes and fittings shall be carefully lowered in the trenches.
Special arrangements such as cranes, tripods with chain pulley block etc. for lowering the pipes
and fittings shall be made by Concessionaire at his own cost. In no case pipes shall be dropped.
Slings of canvas or equally NON ABRASIVE MATERIAL of suitable width and strength or
special attachment to fit the ends of pipes and fittings shall be used to lift and lower the coated
pipes and fittings. The pipes and fittings shall be inspected for defects and, be struck with light
hammer preferably while in suspended position to detect presence of any cracks. If doubt persists,
further confirmation shall be done by pouring a littleParaffin on the inside of the pipe at the
suspected spot and after doing vigilant investigation whether the Paraffin is leaking on to the
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external side of the pipe or not then only the non leaking pipe should be considered fit for use. Pipes
and fittings damaged during lowering or aligning shall be replaced by Concessionaire at no extra
cost.
To protect the persons from injury and to avoid any damage to property, adequate barricades,
construction signs, red lanterns and guards, as required for smooth functioning of work and to avoid
any minor or major accidents, shall be placed and maintained during the progress of the
construction work and until it is safe for the traffic to use the roadways. The relevant Indian
Standards and the rules and regulations of local authorities in regard to safety provisions shall be
observed.
Suitable fencing/barricades shall be provided along the sides of trenches and pits. The posts of
fencing shall be of timber securely fixed in the ground not more than 3 m apart and they shall not
be less than 75 mm. in diameter or less than 1.2 m. above the surface of the ground. There shall be
two rails, one near the top of the posts and the other about 450 mm. above the ground and each
shall be from 50 mm. to 70 mm. in diameter and sufficiently long to run from post to post to which
they shall be bound with strong rope. The method of projecting rails beyond the posts and tying
them together where they meet will not be allowed on any account. All along the edges of the
excavated trenches a bund of earth about 1.2 m. high shall be formed where required by Project
Engineer and Executing Agency (but due care shall be taken while stacking the excavated stuff to
cause least inconvenience for day to day site activities) for further protection. The above work shall
not be paid for separately and the Concessionaire shaft takes into account the costs of such works
and quote accordingly.
Total quantity of water required for entire work including for testing- pipes and fittings at work site
shall be arranged by Concessionaire at his own cost. Dragging of pipes and fittings along concrete
and similar pavements with hard surfaces shall be prohibited.
The road metal and also the rubble packing obtained out of road surface excavations etc. shall first
be stripped off for the whole width and entire length of the trench/pit and separately deposited in
such place or places as may be determined by Project Engineer and Executing Agency. In case of
the metal packing or "Khandkies" not being so deposited or being mixed up with excavated
materials and not available for backfilling and making good the excavation, the cost of the new
metal, packing or "Khandkies" required shall be charged to the Concessionaire.
The portions of trenches in stony or rocky ground are to be excavated all along to the entire length
and for the full depth such that the bottom of the excavation shall not be higher at any point than
the bottom of the concrete' bedding layer below the sewer pipe.
During excavation, large stones and rubble shall be separated and removed from the excavated soil
and stacked separately. The material from excavation shall be deposited on either side of the trench
leaving adequate clear distance from the edges of the trench and pit or as may be necessary to
prevent the sides of the trench/pit to "cave-in" or at such a distance and in such a manner as to avoid
covering fire hydrants, sluice valves, manhole covers etc., and so as to avoid abutting the wall or
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structure or causing inconvenience to the public and other service, organization or otherwise as
Project Engineer and Executing Agency may direct.
Concessionaire also shall take into account while quoting his rates for possible additional
excavations for trial pits of such sizes and depths that may be required to be undertaken by him as
per the instructions of Project Engineer and Executing Agency for determining the locations of
various existing underground service line such as water pipes, drains, sewers, gas pipe lines, electric
and telephone cable etc. which may be met with. Concessionaire should also as per the instructions
of Project Engineer and Executing Agency backfill and thoroughly compact all such additional
excavations and make the area as original after the purpose of locating is served. No additional
payment will be considered by the Executing Agency on this account.
During the pendency of the contract the Concessionaire should take all due precautions for proper
maintenance and protection against damage of all such service lines if met with during excavation,
by means of shoring, strutting, planking over, padding- or otherwise as Project Engineer and
Executing Agency may direct. Also all precautions shall be taken during excavation and laying
operations to guard against possible damage to any existing structures. In case if any such damages
have occurred then those shall be made good either by Concessionaire or by other agency, as
Executing Agency may decide and wholly in either case at the expense of Concessionaire.
If the work for which the excavation has been made is not completed by the expected date of the
setting of monsoon or the setting in of rain whichever is earlier, or before the day fixed by Project
Engineer and Executing Agency for filling in any excavation on account of any festival or special
occasion, Concessionaire shall backfill such excavation and consolidate the filling at his own
expenses as directed by Project Engineer and Executing Agency and shall re-excavate when
required at his own cost.
Project Engineer and Executing Agency may order portions of shoring to be left in the trenches at
such places, where it is found absolutely necessary to do so as to avoid any damage which may be
caused (because of pulling out shoring from the- excavated trench/pit) to buildings, cables, gas
mains, water mains, sewers etc. in close proximity of the excavation. Concessionaire shall be paid
at the negotiated rate for the shoring left in the trenches / pit if directed by Project Engineer and
Executing Agency. Concessionaire shall not claim, for any reasons whatsoever for the shoring
which may have been left in position by him at his own discretion. Concessionaire shall not be paid
for shoring left in the portions of the rakers, struts, or other timber cut off and not permanently left
in the work.
Utmost care shall be taken to see that the width of the trench at the top of pipe is not more than that
as specified. In case additional width is required it shall be provided only in the top portion from
the ground level upto 300 mm. above the crown of pipe. If any extra width is provided in the area
below this portion because of mistake on part of the Concessionaire, Concessionaire shall have to
provide remedial measures in the form of lime concrete or rubble masonry or otherwise at the
discussion and to the satisfaction of Project Engineer and Executing Agency. Concessionaire shall
not be paid any additional for extra excavation as well as for the resulting remedial measures
338
adopted to make up for the additionally done excavation. If rock is met with, it shall be removed to
15 cm. below the bottom of pipes and fittings / specials and the space resulting shall be refilled
with granular materials and properly consolidated. No compensation will be paid to the
Concessionaire on this account and financial implications for the same should be included by the
Concessionaire in his rates. Bottom of trenches / pits shall be saturated with water and well rammed
wherever Project Engineer and Executing Agency may consider it necessary to do so.
Wherever a socket or collar of pipe or fitting / special is to be accommodated a strip sufficient

enough for this purpose is to be cut in the bottom of the trench or concrete bed to a depth of at least
75 mm. below the bed of the pipe so that the pipe may have a fair bearing on its shaft and does not
rest upon its socket. Such strip shall be of sufficient size in every respect to admit the free
movements of hand holding necessary tools of the skilled worker, all around the socket in order to
make the joint completely water tight and the strip shall be maintained clear until the joint has been
approved by Project Engineer and Executing Agency.
All the pipes are to be laid perfectly true both in alignment and to the gradient specified.
When welding is to be carried out with the pipes and specials in the trench, additional excavation
of not more than 60 cm. in depth and 90 cm. in length shall be made at joints in order to facilitate
welding. The excess volume of this excavation should be brought to the acceptable level by making
good with necessary fill material as directed by Project Engineer and Executing Agency. The
charges on this account should be included in his rates by the Concessionaire.
The excess excavated material shall be carried away from site of works to a place up to a distance
as directed by Project Engineer and Executing Agency. This shall be done immediately so as not
to cause any inconvenience to the public or traffic.
5.3 Dewatering
During the excavation, if subsoil water or water mixed with- day/slush- is met with Concessionaire
shall have to provide necessary equipment and labourers for dewatering the trenches/pits by bailing
out water or clay/slush; if pumping out subsoil water is found to be necessary, Concessionaire shall
provide pumps in sufficient numbers/type for the same. In both the above cases the excavation shall
be done to the required level and the pipes shall be laid to proper alignment and gradient.
Concessionaire shall also make foolproof necessary arrangement for the disposal of drained water
to nearby storm water drain or in a pit if allowed by Project Engineer and Executing Agency. In no
case the water shall be allowed to- spread indiscriminately over the adjoining area. Before
discharging this water into public sewer/drain, Concessionaire shall take necessary permission from
all the local authorities before implementing the draining arrangements.
5.4 Special foundation in poor quality soil
Where the bottom of the trench at subgrade is found to consist of material which is unstable to such
a degree that in the opinion of Project Engineer and Executing Agency, it cannot be removed and
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replaced with an approved material thoroughly compacted in place to support the pipe properly, a
suitable foundation for the pipes, consisting of piling, timbers or other materials, in accordance
with relevant drawings and as instructed and approved by Project Engineer and Executing Agency
shall be constructed.
When the work of constructing the pipe lines has to be carried out in soft underground strata, such
as puddle etc. or in a reclaimed land, a good foundation shall be provided for the pipes and
manholes. For the former, excavation in the trench shall be taken 75 mm. deeper than what is
ordinarily required and for this depth the whole of the trench shall be covered over with M-150 bed
concrete of the required width, reinforced with B.R.C. fabric No.9 or any other fabric- approved-
The fabric shall be suitably cut to the requirement and securely joined together with adequate laps
which should not be less than 200 mm. The fabric in the pipe line must also be securely jointed
together. The rates in both the cases shall be held to include all lapping, jointing and also any
probable wastage.
5.5 Wooden shoring
Concessionaire shall suitably design polling boards, walling and struts to meet different soil
conditions that might be encountered in excavating trenches/pits. The horizontal and vertical
spacing of struts shall, be such that not only the sides of trenches shall be prevented from collapse
but also easy lowering of pipe in trenches shall be ensured without creating undue obstructions for
the excavation of the work. Any inconvenience and/or delay that might be caused in lowering pipes
in trenches as a result of adopting improper spacing of struts by Concessionaire shall be his sole
responsibility. No part of shoring shall at any time be removed by Concessionaire without obtaining
permission from Project Engineer and Executing Agency. While taking out shoring planks the
hollows of any form must simultaneously be filled in with soft earth well watered & rammed with
rammers.
Project Engineer and Executing Agency may order portions of shoring to be left in the trenches/pits
at such places, where it is found absolutely necessary to do so as to avoid any damage which may
be caused to the adjacent buildings, cables, gas-mains, water mains, sewers etc. in close proximity
of the excavation, by pulling out the shoring from the excavations. Concessionaire shall not claim,
on any reason, whatsoever for the shoring which may have been left in by him at his own discretion.
5.6 Steel plate shoring
Where the subsoil conditions are expected to be of a soft and unstable character in trench/pit
excavation the normal method of timbering may prove insufficient to avoid subsidence of the
adjoining road surfaces and other services. In such circumstances Concessionaire will be required
to use steel trench sheeting or sheet piling adequately supported by timber struts, walling etc., as
per the instructions, manner and method directed by Project Engineer and Executing Agency.
Concessionaire shall supply, pitch drive and subsequently remove trench sheeting or piling in
accordance with other items of the specification.
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5.7 Boning staves and side rails
In laying the pipes and fittings/specials the centre for each pipe line shall be marked by a peg.
Concessionaire shall dig holes for and set up two posts (about 100 mm. x 100 mm. x 1800 mm.) at
each junction of pipe lines at nearly equal distance from the peg and at sufficient distances there
from to be well clear of all intended excavation, so arranged that a side rail when fixed at a certain
level against the post shall cross the centre line of the manhole / chamber or pipe lines. The side
rail shall not in any case be more than 30 m apart, intermediate rails shall be put up if directed by
Boning staves of 75 mm. x 50 mm size shall be prepared by Concessionaire in various lengths,

each length being of a certain whole number of metres and with a fixed tee-head and fixed
intermediate cross pieces, each about 300 mm. long. The top-edge of the cross piece must be fixed
below the top-edge of this tee-head at a distance equal to the outside diameter of the pipe or the
thickness of the concrete bed to be laid as the case may be. The top of cross pieces shall indicate
different levels such as excavation for pipe line, top of concrete bed, top of pipe etc. as the case
may be.
The side rail of size 250 mm. x 40,mm. shall be screwed with the top edge resting against the level
marks. The centre line of the pipe shall be marked on the rail and this mark shall denote also the
meeting point of the centre lines of any converging pipes. A line drawn from the top edge of one
rail to the top edge of the next rail shall be vertically parallel with the bed of the pipe and the depth
of the bed of pipe at any intermediate point may be determined by letting down the selected boning
staff until the tee head comes in the line of the sight from rail to rail.
The post and rails shall be perfectly square and planed smooth on all sides and edges. The rails
shall be painted white on both sides, and the tee heads and cross piece of the boning staves shall be
painted black.
For the pipes converging to a manhole / chamber at various levels, there shall be a rail fixed for
every different level. When a rail comes within 0.60 M. of the surface of the ground, a higher sight
rail shall be fixed for use with the rail over the next point.
The posts and rails shall be in no case be removed until the trench is excavated, the pipes are laid
and Project Engineer and Executing Agency gives permission to proceed with the backfilling.
5.8 Encasing / being / hunching etc.
The pipes shall be provided with encasement / bedding / hunching etc. as specified in drawings.
5.9 Laying of pipes and fittings / specials
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All precautions shall be taken during excavation and laying operations to guard against possible
damage to any existing structure / pipe line of water, gas, etc. and excavation to proceed in
accordance with the relevant of Clause of this specifications.
All the pipes are to be laid perfectly true both in alignment and to gradient specified In case of
spigot and socket pipe the socket end of the pipe shall face upstream EXCEPT WHEN THE PIPE
LINE RUNS UPHILL IN WHICH CASE THE SOCKET ENDS SHOULD FACE THE
UPGRADE. The laying of pipes shall always proceed upgrade of a slope. After placing a pipe in
the trench, the spigot end shall be centered in the socket and the pipe forced home and aligned to
required gradient. The pipes shall be secured in place with approved backfill material tamped under
it except at the socket. Pipes and fittings / specials which do not allow a sufficient and uniform
space for joints shall be removed and replaced with pipes and fittings/ specials of proper dimensions
to ensure such uniform space: Precaution shall be taken to prevent dirt from entering the jointing
space. At times when pipe laying is not in progress, the open ends of pipe shall be closed by a
watertight plug or other means approved by Project Engineer and Executing Agency. During the
period that the plug is on, the Concessionaire shall take proper precautions against flotation of the
pipe owing to entry of water into the trench: Wherever it is necessary to deflect pipe from a straight
line, either in the vertical or horizontal plane, to avoid obstructions or where long radius curves are
permitted, the deflection allowed at joints shall not exceed 2½°. In the case of pipes, with joint to
be made with loose collars, the collars shall be slipped on before the next pipe is laid. The pipes
shall be laid such that the marking on pipes appears at the top of the pipes.
The cutting of pipe for inserting valves, fittings or closure pieces /specials shall be done in a neat
and workmanlike manner without damage to the pipe so as to leave a smooth end at right angles to
the axis of the pipe. For this purpose, pipe cutting machine shall be used and skilled labourers only
should be allowed to achieve this task.
5.10 Thrust blocks
Thrust blocks shall be provided as design and requirement as defined in the specifications and IS
code and as directed by Project Engineer and Executing Agency to counteract hydraulic thrust, at
places wherever directed and as per relevant drawing.
Where the hydraulic thrust is in an upward direction, anchor blocks as per the relevant drawing
shall be provided to which the pipes shall be secured with steel straps.
5.11 Jointing of pipes
Jointing for pipes and fittings / specials shall be done in accordance with: the relevant specifications
depending on type of pipes being used.
5.12 Testing and commissioning
Testing and commissioning of pipes shall be done in accordance with the relevant specifications.
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5.13 Backfilling
Trenches shall be backfilled with approved selected excavated material only after the successful
testing of the pipe line. The tamping around the pipe shall be done by hand or other hand operated
mechanical means. The water content of the soil shall be as near the optimum moisture content as
possible. Filling of the trench shall be carried out simultaneously on both sides of the pipe in such
a manner that the level of filling rises gradually and unequal pressure does not occur on the pipe.
Backfilling of earth shall be carried out as per IS/CPWD Specifications. Each layer shall be
consolidated by watering, ramming, care being taken not to damage to the pipe line. In case of mild
steel pipes / specials, the spiders provided during assembly and welding shall be retained until the
trench is refilled and consolidated. Where timbers are placed under the pipe line to aid alignment,
these timbers shall be removed before backfilling.
5.14 Reinstatement of road / footpath
Reinstatement of road / footpath shall be done as per requirements of local authorities and the
relevant specifications after the completion of work.
5.15 Clearing of site
All surplus materials, and all tools and temporary structures shall be removed from the site as
directed by Project Engineer and Executing Agency and the construction site left clean to the
satisfaction of Project Engineer and Executing Agency.
6. Measurement
The measurements for excavation in trenches shall be done in following manner and will be paid
accordingly.
(i) Length (L) As per the actual length of pipe and fittings / specials laid at work
site.
(ii) Width (B) O.D. + 600 mm. only where O.D. is the outside dia. of pipes in
mm.
(iii) Depth (D) Average depth of trench from ground level to invert of pipe and
fittings.
Excavation of asphalt road and reinstatement of road shall be measured on per square metre basis
and the length and width at top of trench shall be considered same as those mentioned for
excavation of trench.
The rate for this item should be inclusive of all excess excavated material to be transported from
site of work to a place upto a maximum distance of 5 km. as directed by Project Engineer and
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Executing Agency immediately after his instructions so as not to cause any inconvenience to the
public or traffic.
In case the excavation is done in wet condition either by bailing out water or by resorting to
pumping, the respective items shall be paid according to the items in schedule of quantities and
rates. The measurement for these items shall be made as per the units for relevant item(s) in
schedule of quantities and rates. However, Project Engineer and Executing Agency will decide on
site the mode of dewatering and his decision shall be final and binding on Concessionaire.
Shoring (open/ close) if to be paid separately shall be measured on the square metre basis of the
actual area of trenches shored.
The measurement for removal of excess excavated material upto a specified distance shall be as
per the relevant item(s) in the Schedule of Quantities and Rates and shall be measured on cubic
metre basis. In case of soil 30% deduction shall be done to take account for voids where as it will
be 40% in case of rubble.
Measurement for pipes and fittings / specials shall be in accordance with the relevant clause(s) of
specification for particular type of pipes.
7. Notes
Fencing provided along the sides of trenches and pits shall not be paid for separately and
Concessionaire shall take into account the costs of such works and quote accordingly.
In case of the road metal packing or dressed stones not being deposited as specified or being mixed
up with excavated materials and not available for the reinstatement of road / pavement, the cost of
the new metal packing or dressed stones required shall be charged to Concessionaire by Executing
Agency.
Service lines if damaged during excavation shall be made good either by Concessionaire or by other
agency as Executing Agency may decide and wholly in either case at the expense of
Concessionaire.
Concessionaire shall not be paid any additional compensation for excess excavation over what is
specified as well as for any remedial measures that are specified.
The excess excavated material shall be carried away from site of works as specified, failing which
in view of public safety and traffic convenience at Concessionaire cost.
8. Data Sheet – A
 Hydrostatic Test Pressure at Work Site - 30 m.

 Leakage Test Pressure at Work Site - 30 m.
344
 Bedding - As per drawing
 Width of trench - O.D. + 600 mm. only where O.D is the outside dia. of pipes in mm
345
Section - WS2
Technical specifications for laying of jointing of cast iron pipes and fittings (cast iron)
346
Section - WS2
Technical specifications for laying of jointing of cast iron pipes and fittings (cast iron)
Contents
1. Scope ................................................................................................................................................. 334

2. Applicable codes ............................................................................................................................... 334
3. Laying ............................................................................................................................................... 334
4. Valves ............................................................................................................................................... 334
5. Jointing.............................................................................................................................................. 338
6. Measurement ..................................................................................................................................... 343
7. Data Sheet ......................................................................................................................................... 343
8. Notes ................................................................................................................................................. 343
347
Section - WS2: Technical specifications for laying of jointing of cast iron pipes and fittings (cast
iron)
1. Scope
This specification covers the requirements for collecting from stores / warehouses as suggested by
the Executing Agency, transporting to work sites, laying, jointing and field testing of cast iron pipes
and fittings for the water distribution and transmission Network.
2. Applicable codes
Various operations such as transporting to work sites, lowering in trenches, laying, jointing and
field testing of cast iron pipes and fittings shall comply with all currently applicable standards. In
particular, the following standards, unless otherwise specified herein, shall be referred. In all cases,
the latest revision of the standards shall be referred to. In the event of conflict between any of these
Specifications and the Codes referred, such specifications shall be defined, prepared by the
Concessionaire and submitted to the Project Engineer for approval. The decis ion of Project
Engineer in such case shall be final and binding on the Concessionaire.
a) Cast Iron Pipes - LA Class - IS : 1536

b) Specials (Tees, crosses, bends etc.) - IS : 1538
c) Property connections & Fittings - IS: 1239 (Part I & II)
d) Laying of C.I. pipes -IS: 3114
e) Sluice Valves - IS : 780 and IS : 2906
f) Butterfly Valves (Double flanged long body) - BS : 5155 / IS: 13095
g) Kinetic Double Air Valves with isolating sluice valve - IVC make
h) Fire Hydrants - IS : 908
i) Rubber Gasket for Flanged Connection - IS : 638
j) Ferrules - IS: 2692
k) Specification for rubber sealing rings for gas mains, water mains and sewers. IS:5382
l) Scour valve including C.I. L.A class drain pipe of dia. equivalent to that of Scour valve and 6
m. length IS:780 & IS:2906
3. Laying
For Clauses No.3.0 i.e. Carting and Handling, 4.0 i.e. Storage and 5.0 i.e. Laying - please refer Sub-
Section WS-1 for "Technical Specifications for Laying of Pipes and Fittings / Specials" which are
common for this item also.
4. Valves
4.1. General
348
i. Valves shall be as per internationally recognized standards. Flanges shall be machined on
faces and edges and conform to ISO 7005, IS 6392 or BS 4504.
ii. Valves shall be double flanged type and the face shall be parallel to each other and flange
face should be at right angles to the valve centerline. Back side of valve flanges shall be
machined or spot faced for proper seating of the head and nut.
iii. Valve buried or installed in underground chamber, where access to a hand wheel would be
impractical shall be operated by means of extension spindle and / or keys.
iv. Valve of diameter 450 mm. and above shall be provided with lifting eyes and shall have
detachable bolted covers for inspection, cleaning and servicing.
v. Valve shall be suitable for frequent operation as well as operation after long periods of
idleness in either open or closed position.
vi. The valve stem, thrust washers, screws, nuts and all other components exposed to the water
shall be of a corrosion resistant grade of stainless steel.
vii. Valves shall be free from sharp projections.
4.2. Butterfly valves
(a) Butterfly valve shall be as per IS 13095 / BS 5155. Valve shall suitable for mounting in any
position.
(b) The valve seat shall be secured to the valve body. When the valve is fully closed, a seal shall
seat firmly so as to prevent leakage. The seat surfaces shall be machined smooth to provide
a long life for the seal.
(c) The valve seal shall be replaceable and securely clamped to the edge of the disc by stainless
steel seal retention members, or equivalent so as to prevent leakage and to hold the seal
securely during operation. The seal retention member shall be securely clamped with
stainless steel fasteners. All fasteners shall be set flush so as to offer the least resistance
possible to the flow-through the valve.
(d) Valve shall be suitable for throttling purpose.
(e) All valve spindles and hand wheels shall be positioned to give good access for operational
personnel.
349
(f) Valve of diameter 450 mm. and above shall be provided with enclosed gear arrangement for
ease of operation. The operation gear shall be such that they can be opened and closed by
one man against an unbalanced head 15%in excess of the maximum specified rating. Valve
and any gearing shall be such as to permit manual operation in a reasonable time and not
exceed a required rim pull of 400 N.
(g) All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the
direction of rotation for opening and closing being indicated on the hand wheels
4.3. Sluice valves
(a) Sluice valve shall conform to IS 780 and IS 2906 or relevant internationally recognized
standards.
(b) They shall be of rising or non-rising spindle type depending on application. The valve shall
be furnished with a bushing arrangement for replacement of packing without leakage. They
shall also have renewable channel and shoe linings. The gap between the shoe and channel
shall be limited to 1.5 mm.
(c) The gate face rings shall be screwed into the gate or alternatively securely pegged over the
full circumference.
(d) Valves of 450 mm. and above shall be provided with thrust bearing arrangement for ease of
operation.
(e) Valves of diameter 450 mm. and above shall be provided with enclosed gear arrangement for
ease of operation. The operation gear of all valves shall be such that they can be opened and
closed by one man against an unbalanced head 15% in excess of the maximum specified
rating. Valve and any gearing shall be such as to permit manual operation in a reasonable
time and not exceed a required rim pull of 400 N.
(f) Al1 valves, spindles and hand wheels shall be positioned to give good access for operational
personnel.
(g) All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the
direction to close the valve, the direction of rotation for opening and closing being indicated
on the hand wheels.
4.4. Non-return valve
(a) The valve shall be suitable for mounting on a horizontal pipeline and flow direction shall be
clearly embossed on the valve body.
350
(b) The valves shall possess high speed closing characteristics and be designed for minimum
slam condition when closing.
(c) In case of multi door swing type check valve, the non-slam characteristic shall be achieved
by providing suitable combination of door and hydraulic passages without any external
damping arrangements or passages. The angle of sealing and door weight shall be designed
to provide the most efficient working with least restriction to flow.
(d) Valve of diameter greater than 450 mm. shall be provided, in addition to others, feet and
jacking screws. Hinge pins / shaft shall preferably be square in section to ensure positive
location of flaps and provide for secure fixing.
4.5. Air valves
(a) The valve shall be capable of exhausting air form pipe work automatically when being filled.
The air being released at a sufficiently high rate to prevent the restriction of the inflow rate.
Similarly the valve shall be capable of ventilating pipe work automatically when being
emptied, the air inflow rate being sufficiently high to prevent the development of a vacuum
in the pipelines. The valve shall also automatically release air accumulating in pipe work
during normal working conditions.
(b) Air valve shall be of the double orifice type with a large orifice for ventilation or exhaust of
the pipeline and smaller orifice for automatic release of air under normal working pressure.
(c) Air valve shall be designed to prevent premature closure prior to all air having been
discharged from the line. The orifice shall be positively sealed in the closed position but the
float (ball) shall only be raised by the liquid and not by a mixture of air and liquid spray. The
seating shall be designed to prevent the floats sticking after long periods in the closed
position.
4.6. Pressure relief valves
1. Pressure relief valves shall be capable of relieving pressure in the system to prevent the
system being pressurized in excess of a preset maximum allowable pressure. The valves shall
be drop tight under normal operating conditions.
2. The valve operation shall be achieved by the interaction of the inlet pressure and an
intermediate pressure produced by a pilot valve or relay system acting on the upper side of
the main valves.
351
3. The pilot valve or relay system shall be actuated by a diaphragm connected to the inlet
pressure on its underside and a constant pressure on its upper side derived either from weight
or from a spring.
5. Jointing
5.1. Tyton joints
The rubber rings shall be stored in a cool dark, dry and dust free environment. The storage location
shall not be exposed to direct sunlight or any heat radiating appliances. The rings shall not be
allowed to come in contact with any fuels and shall be stored free of tension.
Rubber rings shall be clearly labeled in bundles to indicate the type of ring, the size of pipe which
they are to be used, the manufacturer's name or trademark and the month and the year of the
manufacture.
The rings shall comply with IS:5382 regarding their material finish, tolerance in dimensions and
physical requirements. Rubber ring bundles from every lot shall carry with them manufacturer's
test certificate showing the results of following tests:
[a] Hardness
[b] Tensile Strength
[c] Compression test
[d] Oil immersion test
[e] Water absorption test
[f] Stretch test and visual examination
The test procedures, the scale of sampling and the criteria for acceptance shall be as per IS:5382
and lS:3400.
The rubber rings shall be such that they shall not show any signs of deterioration for any reasons
during the contract period plus the defects liability period. Entire expenses associated with
correcting defects in this regard including replacement of rubber rings shall be fully borne by the
Concessionaire.
In jointing cast iron spigot and socket pipes and fittings with tyton flexible joints, the
Concessionaire shall take into account the manufacturer's recommendations as to the methods and
equipment to be used in assembling the joints, in particular the Concessionaire shall ensure that
thespigot end of the pipe to be jointed is smooth and has been properly chamfered, that the rubber
ring as per IS::5382 is correctly positioned in the socket and that the two pipes are accurately in
line, before the joint is made. The rubber rings and any recommended lubricant shall be procured
only through the reputed pipe supplier or as directed by the Project Engineer and Executing Agency.
352
5.2. Flanged joints
In case of flanged joints, the jointing material used between flanges of pipes and fittings shall be
compressed fibre board or rubber conforming to IS:638 of thickness between 1.5 mm. to 3 mm.
The fibre board shall be impregnated with chemically neutral mineral oil and shall have a smooth
and hard surface. Its weight per sq.m. shall be not less than 112 g./mm. thickness. Each bolt shall
be tightened a little at a time taking care not to tighten the bolt which is located immediately
adjacent to the tightened bolt and the bolt which is located diametrically opposite each other should
alternatively be tightened.
The practice of fully tightening the bolts one after another shall not be allowed. The bolts shall be
of mild steel unless otherwise specified.
5.3. Lead caulking joint
The jointing shall be done with molten lead and spun yarn. Pig lead shall be of uniform quality,
clean and free from any impurities and any foreign materials. It shall be of uniform softness capable
of being easily caulked or driven. It shall conform to IS::782. Spun yarn shall be of clean hemp and
of good quality. It shall conform to IS: 65S7. The quantity of lead and spun yarn to be used for
jointing of different diameters of C.I. pipes and fittings shall be as per Table 1 of IS::3114.
Lead shall be heated in a melting pot kept in easy reach of the joint to be poured so that the molten
metal will not be chilled in being carried from the melting pot to the joint and shall be brought to a
proper temperature so that when stirred it will show a rapid change of colour. Before pouring, all
scum shall be removed. Each joint shall be made with one continuous pour filling in the entire joint
space with solid lead. Spongy or imperfectly filled joints shall thoroughly cleaned by
heating/burning till all the contents of the imperfectly tilled lead in the joint are cleared. After
clearing the joint it should be re-poured as per the original procedure.
The joint runner shall fit snugly against the face of the socket and a bund of clay should be made
on outside of the pipe to form a pouring lip to provide for filling the joint flush with the face and
to the top of the socket.
The jointing is done by first caulking in spun yarn, then filling the remainder of the joint space by
running in molten lead, taking care that no dross enters the joint, and then thoroughly caulking the
lead. The spun yarn shall be used to centre the spigot in the socket and to prevent the flow of molten
lead into the bore of the pipe.
After the lead has been run into the joint the lead shall be thoroughly caulked. Caulking of joints
shall be done after a convenient length of the pipes shall been laid and leaded. The leading ring
shall first be removed and any lead outside the socket shall be removed with a flat chisel and then
the joint caulked around three times with caulking tools of increasing thickness and hammer of 2
kg weight. Lead run joints shall be preferably finished 3 mm. behind the socket face. The joints
shall not be covered till the pipe line has been tested under specified hydrostatic test pressure,
353
though the rest of the pipe line should be covered up to prevent expansion and contraction due to
variation in temperature.
5.4. Proposed jointing of C.T. pipes
It is proposed to use spigot and socket pipes with rubber ring tyton joints and flanged joints for
valves and other appurtenances.
The pipeline shall be laid such that the socket ends should face the upstream on level ground. When
the line runs uphill the socket end should face the upgrade.
Whenever valve or hydrant connection is to be made socket and flanged specials or T specials as
shown in the drawings shall be used.
In case of rubber ring joints, the groove and the socket shall be thoroughly cleaned before inserting
the rubber gasket. While inserting the gasket, it shall be made sure that it takes the proper direction
and that it is correctly seated in the groove. After cleaning dirt or foreign materials from the plain
end, lubricant shall be applied in accordance with the pipe manufacturer's recommendations. The
plain end of the pipe shall be pushed into the socket of the pipe and while pushing, the pipe shall
be kept straight. If any deflections are to be made in the alignment, it may be made after the joint
is assembled.
For joints between pipe and valve, socket and flanged specials shall be used. The gasket used
between flanges of valves and pipe shall be compressed fibre board or natural / synthetic rubber
(IS::63S) of thickness between 1.5 to 3.0 mm. The fibre board shall be impregnated with chemically
neutral mineral oil and shall have a smooth and hard surface. Its weight per square meter shall be
not less than 112 g/mm thickness. Each bolt should be tightened a little at a time taking care to
tighten diametrically opposite bolts alternatively. The practice of fully tightening the bolts one after
another is highly undesirable.
5.5. Property connections
A property connection should consist of following parts
(i) Brass ferrule

(ii) Communication pipes with couplings, bends, elbows, union etc. (Length as per drawings)
(iii) Cap at the end of the communication pipe near the plot boundary.
The plot Executing Agency is expected to construct and connect the remaining portion of property
connections at plot boundary. The desired arrangement of property connection is shown in Drawing
No.15-A-101.
5.6. Connection at main
354
Boring on water main should be done on top of main to reduce possible entry of silt into pipe and
subsequently damaging of meters. A manual drilling and tapping machine should be used for this
purpose. A bore shall be drilled and tapped on CI main and a ferrule shall be screwed directly into
the bore. Upto 38 mm size of property connections, ferrules shall be used where as for higher size
property connections, T connection shall be given. Ferrule shall be of gunmetal or brass as per IS:
2692. The ferrule should be so set in the main that the communication pipe leads off in line with
the main before curving round right handed into its proper course as show in Drawing No. 15-A-
I01. G I. Pipes to be used as property connections shall confirm to IS: 1239. Class C. the pipe
should be provided, external protection of bitumen coating with hession cloth wrapped over it. It
should be provided with PVC sheathing wherever they are exposed such as in case of drain
crossings.
The specials to be used at crossing of pipelines, T joints, 90 deg. bends and valve joints are shown
in the Drawing No. 15-A-101.
5.7. Testing
After the pipes and specials are laid, jointed and the trench partially back filled except at the joints
the stretch of pipe line as directed by Project Engineer and Executing Agency shall be subjected to
pressure test and leakage test. Where any section of the rising main is provided with concrete thrust
blocks or anchorages, the pressure test shall not be made until atleast five days have elapsed after
the concrete was cast. If rapid hardening cement has been used in these blocks or anchorages, the
test shall not be made until atleast two days have elapsed after concreting.
Each section of pipe line shall be slowly filled with water and all air shall be expelled from the pipe
by tapping at points of highest elevation before the test is made and plugs inserted after the test
have been completed. Specified pressure as per Data Sheet A, based on the elevation of the lowest
point of the line or section under test and corrected to the elevation of the test gauge, shall be applied
by means of a pump connected to the pipe as directed by Project Engineer and Executing Agency.
The duration of test shall not be less than 5 minutes. Where the field test pressure is less than two-
third the work test pressure, the period of test should be increased to atleast 24 hours. If a drop in
pressure occurs, the quantity of water added in order to re-establish the test pressure should be
carefully measured. This should not exceed 0.1 litre/mm, dia. per km. of pipe line length per day
for each 30 m. head of pressure applied. The exposed joints shall be carefully examined and all
such joints showing visible leaks shall be rectified until it becomes fully water tight. Any cracked
or defective pipes and fittings as a consequence of this pressure test shall be removed from site and
replaced by acceptable quality of pipes by Concessionaire and the test shall be repeated to the
satisfaction of Project Engineer and Executing Agency.
After the satisfactory completion of pressure test, the section of pipeline shall be subjected to
leakage test at a pressure as specified in Data Sheet A. The duration of test shall be 2 hrs. No pipe
installation shall be accepted until the leakage is less than the number of CUM./hr. as determined
by the formula;
355
qL = ND √p
3.3
where,
q L = the allowable leakage in CUM./hr.

N = number of joints in the length of the pipeline
D = diameter in mm. and
p = the average test pressure during the leakage test in kg./sq.cm.
Should any test of pipe laid disclose leakage greater than that specified above the defective joints
shall be repaired by Concessionaire at no extra cost to the Executing Agency until the leakage is
within the specified allowance.
Necessary equipment and water used for testing shall be arranged by Concessionaire at his own
cost. Damage during testing shall be Concessionaire's responsibility and shall be rectified by him
at no extra cost to the Executing Agency. Water used for testing shall be drained out from the pipe
to safe location and should not be released in the excavated trenches.
After the tests mentioned above are completed to the satisfaction of Project Engineer and Executing
Agency, the backfilling of trenches shall be done as per specification.
5.8. Disinfection of water mains
The mains intended for potable water supplies should be disinfected before commissioning them
for use.
After pressure testing the main, it should be flushed with water with sufficient velocity to remove
all dirt and other foreign materials. When this process has been completed the process of
disinfection (using liquid chlorine, sodium or calcium hydrochloride) can proceed by one of the
following methods.
5.9. Continuous feed
In this method, water from the distribution system or other approved source and the chlorine are
fed at a concentration of atleast 20 to 50 mg./litre. A properly adjusted hydrochloride solution
injected into the main with a hydro chlorinator, or liquid chlorine injected into the main through a
solution feed chlorinator and booster pump shall be used. The residual chlorine should be checked
at intervals to ensure that the proper level is maintained. Chlorine application should continue until
the entire main is filled. The water should remain in the main for a minimum of 24 hours, during
which time all valves, hydrants, etc. along the main should be operated to ensure their proper
disinfection. Following the 24 hours period not less than 10 mg./l. residual chlorine should remain
in the main.
356
5.10. Slug method
In this method a continuous flow of water is fed with a constant dose of chlorine but with rates
proportioned to give a chlorine concentration of atleast 300 mg./l. The chlorine is applied
continuously for a period of time to provide a column of chlorinated water that will contact all
interior surface of the main for a period of atleast three hours. As the slug passes tees, crosses etc.,
valves must be properly operated to ensure their disinfection. This method shall be used principally
for large diameter mains.
Regardless of the method used, it is necessary to make certain that back flow of the strong chlorine
solution into the supplying line does not occur. The' chlorinated water should be flushed to waste
until the remaining water has a chlorine residual approximating to 0.2 tng./l. that throughout the
rest of the system bacteriological tests should be taken and if the result fails to meet minimum
standards, the disinfecting procedure must be repeated and the results again tested before placing
the main in service.
6. Measurement
The measurement for pipe laying shall be on running metres of net length along the centre line of
pipe as laid including specials. The length of pipes shall not include the portion of spigots within
the sockets of fittings and pipes.
The rate for providing and laying of C.I. pipes shall be deemed to include the extra excavation
required for ordinary bedding of pipes as per IS: 783 and also for sockets or flanges if any and cost
of jointing material.
6.1. Procedure of measurements
i. Length (L): As per the actual length of pipe and fittings / specials laid at work site.
ii. Trench Width (B): For payment of excavation, the width of trench shall be considered as O.
D. + 600 mm. only where O.D. is the outside diameter of the pipe in mm.
iii. Depth (D): Average depth of trench from ground level to invert of pipe and fittings.
7. Data sheet - A
7.1. Hydrostatic test pressure at work site - 30 m
7.2. Leakage test pressure at work site - 30 m.
7.3. Bedding - As per drawing
8. Notes
Fencing provided along the sides of trenches and pits shall not be paid for separately and
Concessionaire shall take into account the costs of such works and quote accordingly.
357
In case of the road metal packing or dressed stones not being deposited as specified or being mixed
up with excavated materials and not available for the reinstatement of road / pavement, the cost of
the new metal packing or dressed stones required shall be charged to Concessionaire by Executing
Agency.
Service lines if damaged during excavation shall be made good either by Concessionaire or by other
agency as Project Engineer and Executing Agency may decide and wholly in either case at the
expense of Concessionaire.
Concessionaire shall not be paid any additional compensation for excess excavation over what is
specified as well as for any remedial measures that are specified.
The excess excavated material shall be carried away from site of works as specified, failing which
in view of public safety and traffic convenience Executing Agency / Project Engineer may carry
out the work by any other agency at Concessionaire's risk and cost.
Portion of shoring left in the excavated trenches or pits shall be measured and paid separately, if
instructed by Project Engineer and Executing Agency to do so.
358
Section G4.1
General mechanical specifications
359
Section – G4.1
General mechanical specifications
Contents

1. General requirements ........................................................................................................................ 361
2. Relevant standards ............................................................................................................................ 363
3. Pumping systems .............................................................................................................................. 364
4. Pipe work .......................................................................................................................................... 364
5. Isolation and drain down ................................................................................................................... 367
6. Grit removing equipment .................................................................................................................. 370
7. Clarifier mechanism .......................................................................................................................... 370
8. Aeration tank & Equipment .............................................................................................................. 371
9. Decanters for SBR ............................................................................................................................ 374
10. Gravity sludge thickener ............................................................................................................... 375
11. Gas generating set & accessories ................................................................................................. 377
12. Sludge dewatering units ................................................................................................................ 379
13. Pumps ............................................................................................................................................ 379
14. Polyelectrolyte solution preparation and dosing system ............................................................... 388
15. Dismantling Joints ........................................................................................................................ 389
16. Valves ........................................................................................................................................... 389
19. Electrical Overhead Traveling (EOT) crane ................................................................................. 401
20. Manually Operated Overhead Crane/Hoist ................................................................................... 402
21. Emergency equipment (General) .................................................................................................. 403
22. Ventilation & odour control .......................................................................................................... 403
23. Water and wash water supplies ..................................................................................................... 409
360
Section G4.1: General mechanical specifications
1. General requirements
All new and rehabilitation works shall use the best engineering practices, material workmanship and quality
of goods to be repaired/rehabilitated and shall comply with the following general guidelines. All Facilities
shall have assured performance. The Concessionaire shall be solely responsible and liable any damage to
the existing/rehabilitated structures during installation of electromechanical works. At all Facilities being
developed or restored and rehabilitated -
1) Sufficient space shall be provided between components of different Facilities or fixed structures to
permit safe and convenient access for operation and maintenance.
2) Layout of the site structures/equipment shall be cognizant of code distances required between non-
hazardous and hazardous structures/plant/equipment, etc. Sludge Management System should have a
separate entry/exit and it should be separately kept away from the main entrance gate and Admin block.
3) An area adjacent to all mechanical equipment shall be provided as maintenance lay down area.
4) Electrically operated cranes, fixed runways, lifting eyes or other means shall be provided to permit
the removal of larger items of different Facilities that may logically be required to be removed during the
course of its normal operational life for maintenance or replacement purposes.
5) Areas where leakage of water /wastewater/ sludge is likely to occur, whether in normal use or
during maintenance, shall be provided with covered drainage channels or pumped dewatering system which
shall direct spillage either to a suitable drain or to a sump from where it can be pumped to an appropriate
place for safe disposal.
6) Where necessary, equipment shall be provided with acoustic, sound-dampening enclosures to limit
ambient noise during normal operation to less than 85 dB at 1.85 m from the equipment. Such enclosures
shall include ventilation and/or cooling provisions as necessary to prevent overheating and ensure operation
of equipment at optimal temperature. CPCB and other applicable standards and guidelines shall be strictly
adhered to particularly for DG sets/Bio Gas Engines/Dual Fuel Genarator Sets and other machinery.
7) Wherever the electric motors, gear box are exposed to open atmosphere, a suitable sunshade shall
be provided.
8) Pipework shall be designed and installed to prevent blockages and to permit their clearance without
dismantling pipework or equipment.
9) The Concessionaire shall take due regard to the potential of hazardous mixing of chemicals,
particularly as a result of leaks and spillages, and their drainage and containment.
10) Chemical pipework shall be secured to racks or trays, to walls of tanks and walls of buildings as
necessary. It shall be arranged to facilitate maintenance and removal of individual runs without dismantling
adjacent pipes.
361
11) All chemical pipes shall be colour banded and suitably labelled to enable individual lines to be
identified with the stream designation and direction of flow at suitable minimum 5- meter intervals
throughout their run.
12) The Concessionaire shall provide all signage necessary to inform of chemical and operational
hazards and to comply with statutory legislation. Also the Concessionaire shall provide display board at all
Facilities at suitable location indicating details of machinery i.e. pumps, blowers, DG sets etc as directed.
13) The Concessionaire shall perform a complete Hazardous Area Classification analysis as per IS
5572 for all Facilities and their components, as relevant, and shall submit a complete report of such analysis
as well as Hazardous Area Classification Drawings that delineate boundaries of all classified areas and
indicate the classification of each area. All electrical or other powered equipment, instrumentation, or
components shall fully comply with all requirements of IS 5571.
14) All components (including but not limited to equipment such as pumps, blowers, screens, diffusers,
inline devices; instruments such as flow meters; and distribution and collection channels or pipes) shall be
provided with appropriate isolation devices such as valves, gates, or other devices in order to allow
isolation, drainage, cleaning, calibration, servicing, and maintenance of such components. Bypasses shall
be provided around all flow meters and other in-line instrumentation such that the instrument can be isolated
and removed for calibration and maintenance without interrupting the flow, regardless of whether or not
such bypasses are shown in any drawings included in the Tender Document.
15) All liquid or sludge flow distribution shall be accomplished using one of the following options
only:
a. non-submerged (i.e. with a positive free fall from weir invert to the downstream water surface)
overflow weirs,
b. non-submerged downward opening overflow weir gates,
All gas flow distribution shall be using PLC-based automatic feedback flow control using inline
flow measurement and modulated flow control valves with electric actuators. Any other means of flow
distribution shall not be acceptable.
16) All piping shall be fully and adequately supported and braced to comply with all applicable codes
and standards. Pipe supporting hardware shall also be of corrosion-resistant material. The design of pipe
supports and anchors shall fully account for static and dynamic vertical, lateral, longitudinal, and seismic
loads, fluid flow, and thermal expansion. Seismic bracing, thrust restraints and/or thrust blocks, and
appropriate expansion joints or loops shall be provided as needed. Pipe lengths and joints shall be assembled
and arranged for ease of removal in such a way that individual runs can be changed without dismantling
adjacent pipes, by providing dismantling joints at regular intervals
17) For liquids and sludge, the minimum velocity of full flow in pipes or conduits shall not be less than
0.6 m/s and the maximum shall not be more than 1.5 m/s for pump suction and not more than 2.1 m/sec on
delivery side of horizontal pump and in case of submersible pump not more than 2.5 m/s for pumped
discharge. All mixed liquor and sludge pipes shall be provided with appropriate cleanouts and flushing
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arrangements for safe and easy flushing using high-pressure water. The normal pipeline peak flow velocity
for gases shall not be more than 20 m/s.
18) For liquids and sludge, the minimum velocity of flow in open channels or partial flow in pipes or
conduits shall not be less than 0.6 m/s and the maximum shall be no more than 1.5 m/s.
19) All piping shall be arranged without clutter and shall be functional and neat in appearance. Where
piping is installed in ducts, it shall be supported not less than 150 mm above the floor.
20) All piping routed under any type of structure or equipment shall be fully and completely encased
in cement concrete, with the encasement thickness beyond the outer diameter of the pipe being at least 200
mm on all sides. The encasement shall extend along the pipe length for a minimum horizontal distance of
1500 mm in each direction beyond the footprint of the overlying structure or equipment.
21) All piping connecting to, entering, or exiting any and all structures shall be provided with
appropriate restrained flexible connections and/or joints at all such interfaces with structures to allow for
differential movement between pipe and structure in all directions without stressing or breaking the pipes.
22) Appropriate restrained flexible connections and/or joints shall be provided for all pipes where they
connect to any and all of the following:
a. Equipment such as pumps, blowers, or inline devices
b. Valves
23) The handrail shall be on min SS 304 Schedule 10 with 1500 mm C/C spacing, double row with
post of 32 NB and running rail of 25 N
24) Provision of all pumping systems for SPS and MPS with standby pump sets, compressors and
blowers of the same type and capacity as the duty pumps, providing a standby capacity of not less than
100% of the total duty.
2. Relevant standards
The design, manufacture, supply, storage of all equipment shall comply with all Indian Standards,
(or in the absence of Indian Standards, the appropriate International Standards), Applicable Laws, including
local statutes covering:
1) Health and Safety
2) Dangerous Goods
3) Factories and Commercial Premises
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4) Buildings
5) Electricity Regulations and Codes of Practice
The Standards referred shall form part of this Concession Agreement. Other Standards, Codes of
Practice and Regulations not referred to, but which would be applicable to the design, manufacture,
installation, testing or commissioning of the equipment under this Concession Agreement shall be deemed
part of the Concession Agreement.
3. Pumping systems
In Facilities where it is applicable, the following specifications would be applicable to pumping systems –
1) Provisions of pumping systems with isolation valves, non-return valves, and all necessary pipework
and fittings.
2) Provision of pipe supports, hangers and anchors to support and control movement of pipes and
valves all in accordance with recognized international piping standards.
3) Unless otherwise specified, provision of all pumping systems with standby pump sets of the same
type and capacity as the duty pumps, providing a standby capacity of not less than 100% of the total duty.
All pumps shall operate at high efficiency throughout their duty range and they shall be capable of
continuous operation throughout their required operational range. The minimum diameter of pipe for sludge
transfer shall be 150 mm.
4) Lubrication arrangements shall be designed to avoid any contamination of pumped fluid.
5) Dry well mounted pumps shall provide effective means for collecting gland/seal leakage water
which shall be piped to a floor drain or sump.
6) Hydraulic retention time for wet well shall be as per guidelines CPHEEO/NRCP/NGRBA and wet
well shall be in two compartments which can be isolated.
4. Pipe work
1) All pipework employed shall comply with the schedule below. It is the responsibility of
the Concessionaire to ensure compatibility of all pipelines with fluids or sludge carried
and with external and internal loadings and pressures. All materials of construction for
tanks, vessels, pipelines, pumps, valves, etc. shall be suitable for long term contact with
the liquid or chemical concerned and at the prevailing concentrations. Equipment shall be
coated and protected in accordance with painting and protective coatings.
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Service Size range Pipe material
Potable and raw water Up to and including DN Ductile iron (DI)/GI
including supernatant 300 Unplasticised polyvinyl chloride
(uPVC)
Poly-ethylene (PE)
DN 300 – DN 600 Ductile iron (DI)
Steel
Greater than DN 600 Ductile iron (DI)
Sewage (pumped All diameters Ductile iron (DI)
below ground)
Above ground pipe- Up to and including DN Ductile iron (DI)

work and within 300 uPVC
structures Steel
Steel
All sewage pipework Up to and including DN Ductile iron (DI)
underneath structures 300
Steel
Stainless Steel (316L)
All pipes under roadways & structures to
be concrete encased.
Compressed air All diameters Galvanised mild steel
Sampling All diameters (uPVC) Heavy duty

Instrumentation All diameters Copper (plain/coated)
process piping uPVC
Nylon
Stainless steel
Chemical dosing All diameters Sch. 80 uPVC &According to
manufacturer’s recommendations
Natural Gas MDPE below ground
Stainless steel or steel above
ground/inside buildings
Sludge All diameters Ductile iron K-9
Biogas All diameters Stainless steel 316L (below ground,
inside/outside buildings)
Process Air piping Blower discharge – Ductile iron or Galvanized Steel

Distribution piping around
aeration tanks - All
diameters
Drop legs and Headers Stainless steel (304L)
(under water)
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Service Size range Pipe material
Diffuser grid (manifolds Diffuser grid of uPVC/Stainless steel
and air distributors) (304L) and Anchors bolts, nuts
fasteners, supports and clamps of SS
304.
a) Cast iron pipes
• The cast iron pipes shall generally conform to IS:1537/IS:1536 and pipe fittings shall conform to
IS: 1538. All pipes and fittings above the ground level and inside pumping station shall be flanged.
• The material for cast iron pipes and fittings shall be of grey cast iron conforming to IS: 210, Gr FG
200.
b) Ductile iron pipes
• The DI pipes conform to IS 8329 /ISO 2531/BS EN 545 & fitting conform to IS 9523/BS EN:545.
These pipes can also be offered with standard thickness for smooth flow and corrosion resistance.
c) DI Specials/Fittings
• DI specials shall be manufactured as per IS: 9523 and shall be ISI marked. In case of flanged joints,
the flanges shall be at right angles to the axis of the pipe machined on the face.
• The bolt hole circle shall be concentric with the bore and bolt holes shall be located off the centre
lines as per IS: 9523. Fittings shall be tested as per IS: 9523
d) Stainless Steel Pipes
• All gas pipes, fittings and other related components inside the digester shall be of stainless steel
SS-316.
• All steel pipes shall conform to IS:3589.ERW steel pipes (200mm to 2000mm) for gas, water and
sewage and laying should conform to IS:5822.
e) Unplasticised Polyvinyl Chloride (uPVC) pipes
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• The materials used in the manufacture of uPVC pipes and fittings shall comply with the physical
properties indicated in relevant specification. They shall not contain any matter which could impart taste,
odour, toxicity or be harmful to health or adversely affect the water conveyed.
• Unless specified otherwise joints shall be of the complying with BS 4346/IS4985 having an
elastometric sealing ring. Joints shall be made in accordance with the Manufacturer’s instructions.
• Fittings shall be injection-moulded in uPVC to the requirements of BS 4346/IS4985.
5. Isolation and drain down

In Facilities where it is applicable, provision of facilities for isolating and draining down all pipework,
chambers and storage tanks. Wherever duty/standby equipment is provided, it shall be possible to isolate
and drain-down each of the duty or standby items while the other items are in service.
Coarse Screen In Facilities where it is applicable, Coarse screens shall be installed at the Interception and
Diversion works. The material of construction shall be SS 304. The flats of the screen shall be 50 mm X 10
mm with clear opening of 50 mm. The inclination of the screen shall be maximum 600 to the horizontal. A
suitable SS 304 hand rake for cleaning the screens shall be provided.
Medium and fine screens shall be provided for SPS (20 mm preferably) and STP. All mechanically cleaned
screens shall be provided with mechanically/manually cleaned standby of 100% capacity. In Facilities
where it is applicable, the following specifications would be applicable to medium and fine screens.
• Scope of supply
The scope of supply shall provide complete automatic mechanical screen systems with all accessories and
appurtenances, including, but not limited to:
• Mechanically operated screen;
• Screenings collection, washing and disposal system;
• Automatic screen control system;
• Electrical & instrumentation for compliance of automatic system (electrical wiring between all
screen components, instruments, control devices and the local control panels and the screen controls)
• Guaranteed flow rate and head loss
The screen shall effectively screen all flows up to the design flow. Provision of guarantee the following
screen performance parameters:
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• Clean water flow rate capacity (l/s) at the maximum allowable water depth downstream of the
screen
• Clean water head loss at the max flow rate and maximum allowable water depth downstream of
the screen
• Screening arrangements
Provision of automatic mechanical fine screen to remove particles larger than 6mm size is required.
It is proposed to install sufficient number of appropriately sized automatically operated mechanical fine
screens (stainless steel grade – SS316) of opening size 6mm for screening out floating materials such as
plastic pouches, bags, rags, floating debris, weeds, paper wastes and other floating materials from the
Influent coming from the pumping station. Capacity of the channels shall be equal to 100% of peak flow.
Fully automatic mechanical screen along with the level sensing instrument for automatic operation of screen
mechanical and allied accessories, (local control panel near screen,) shaft less screw conveyor with/cum
compactor are to be provided.
The fixed as well as movable bars/ perforated band, mechanism, support frame, fixings discharge chute
shall be manufactured from stainless steel grade 304 for long life in the aggressive sewage environment.
• Automatic screen clearing and screenings removal
The screen shall be provided with the necessary controls and sensors to anticipate blockage of the screen,
and automatically clear the screen and remove the accumulated screenings from the screen surface. The
screen shall operate automatically when the upstream water level increases beyond a pre-set limit and it
shall stop when the upstream level decreases to pre-set low level.
• Screenings conveyance
The screening system shall be supplied convey the screenings to the automatic screenings press and
discharge system that discharges the screenings through a chute to the screenings storage system.
• Screenings discharge chute
The screenings discharge chute shall terminate 1.5 meters above ground level. A plastic screenings bag
shall be secured around the chute, thereby creating a totally enclosed screenings collection system.
• Screen covers
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All screenings equipment shall be supplied with integral stainless steel covers that prevent access to moving
and wash water sprays. The covers need to be airtight to ensure that no odours emanate from the screen.
• Portable screenings container
Portable screenings containers made of galvanised steel duly epoxy painted shall be provided to store the
screenings until time of pick up. The container shall have capacity of approximate 5 m3 and shall be of a
convenient height to permit the discharge of screenings directly into the container without having to transfer
the screenings manually.
• Electrical motor for Screens
The motor shall be TEFC type with IP 55 protection & Class F insulation and shall be suitable for operation
on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors shall be squirrel cage type conforming to IS
325. The power rating of motor shall be at least 125% of maximum power requirement.
• Control panel for screens
The control panel shall have IP 65 protection, painted with epoxy paint and shall be comprise:
- Mushroom head emergency stop.
- Overload relays for motor protection.
- MCB’s, HRC Fuses and Glass Fuses.
- Circuitry to operate the screen with level sensors.
- Selector switch to operate the screen on JOG mode.
• Access
Safe access shall be provided to all screen equipment and instruments to allow for cleaning, inspection
and maintenance activities.
• Corrosion resistance
All metal parts of the screen equipment that are in contact with the sewage shall be constructed of a
suitable grade of corrosion resistant stainless steel, aluminium or plastic.
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6. Grit removing equipment
In Facilities where it is applicable, the grit chambers shall conform to the best industry practices.
Material of Construction:
a. All wetted parts shall be in SS 316.
b. Air Lift pump (if used ) SS 316
c. Turbo Grit Pump (if used ) : Hardened SS316 impellers, Ni hard volute, Stainless Steel shaft,
heavy-duty bearings and mechanical seal
d. All parts above water, i.e. components like mechanism support etc. shall be in Hot Dip galvanised
structure
e. Hand Railing in SS316 Drive Mechanism of Grit Scrapper
f. Classifier : SS 316 with hardened scraper / tips
g. Portable grit container shall be Hot dip galvanised structure.
The grit removal device shall be capable of removing the following at the specified hydraulic peak flow
rate, and no decrease in efficiency will be allowed at flows less than this design rate.
- 95% of the grit greater than 150 microns in size,
- 90% of the grit greater than 100 but less than 150 microns in size,
7. Clarifier mechanism
In Facilities where it is applicable, the clarifier mechanism shall be suitable for installation in RCC tank
and circular radial flow fixed bridge with scum collector, central turn table type clarifiers shall be provided.
Clarifier should be rugged and robust in design and should be provided with high capacity drive head having
high torque rating, centrally located with positive sludge raking by means of two raking arms.
The mechanism shall comprise but not limited to the following main components:
Bridge superstructure spanning half the tank diameter with central maintenance platform, Drive assembly
complete with drive head, chain & sprocket, geared motor etc., feed well, center cage, cone scraper, rake
arms, tie rods for rake arms, plow blades & squeegees, scum blade & skimmer assembly, A-frame supports
for the skimmer assembly, Scum trough and ramp with support angle, scum baffle with supports and weir
plate.
Feed Well SS 304, minimum 3 mm thick
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Bridge , 1200 mm Wide MS with Hot dip Galvanized (galvanizing minimum thickness shall be 80
micron) (welded/nut bolted/riveted truss in a consolidated single component and no site welding shall be
allowed), grating/checkered plate 6 mm thick
Rake Arm SS 304, minimum 5 mm thick
Center Cage SS 304, minimum 5 mm thick
Rake Blades SS 304, minimum 5 mm thick
V-notch weir SS 304, minimum 6 mm thick and 300 mm wide
Squeegees Neoprene rubber, 10 mm thick, adjustable type
Walkway MS with Hot dip Galvanized (galvanizing minimum thickness shall be 80 micron)
Handrail (both ways in two layers minimum 1.25 m high) 40 NB SS Pipe 32 mm dia vertical and
top rail with 25 mm dia middle level . The hand rail on both sides of bridge shall have a toe plate made of
100 mm wide x 5 mm thick hot dip galvanised .
Scum skimmer assembly SS 304, minimum 5 mm thick and 300 mm wide
Scum Box SS 304, minimum 3 mm thick
Scum Baffle and support bracketes SS 304, minimum 3 mm thick and 400 mm wide
Fasteners – Under Water SS-316
Fasteners – Above Water Galvanised
Current Density baffles (like Stamford Weirs ) MS sheet 4 mm thick with 3 mm FRP voating Or
Moulderd FRP / PVC
8. Aeration tank & Equipment

8.1 Submersible mixers in anoxic tank / sludge storage tank
The anoxic mixers shall be of robust construction, designed for continuous operation under the most
difficult operating conditions installed in three aeration basins. The anoxic mixers shall be energy efficient.
Submersible type mixer with motor housing in CI IS 210 Gr FG 250 and 3 blades propeller in SS 316
construction with suitable motor at 415 ± 10% V, 50 C/S. The submersible mixer shall be complete with
lifting device comprising of MS Hot galvanized 60mm tube, MS winch and steel rope and handle with all
accessories.
8.2 Air blowers
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1) Blowers shall be designed to give clean, dry and oil free discharge. Each blower shall be provided
with a coupling guard and motor and the whole assembly shall be mounted on a heavy duty rigid steel base-
plate.
2) Blower/motor and variable air delivery system shall be of the automated type designed to save
energy while matching air requirements in the aeration tanks at all times.
3) Volumetric efficiency shall not fall to a level where it adversely affects air temperature rise and
overall blower efficiency.
4) Operating pressure shall not be greater than 85% of blower maximum continuous pressure rating.
Bearing design life should be 100,000 hours.
5) For all blowers, standard atmospheric conditions of 20oC and 1013 mbar will be used with
corrections for local ambient conditions for altitude, temperature and relative humidity.
6) The selection of the blowers shall include for losses for silencers, check valves and drive system,
which must be included in the total power figure staged and the blower speed must be adjusted to take such
losses into account.
7) The electric motors shall be a high efficiency type suitable for minimum 415v/3ph/50Hz and
suitable for outdoor wet weather/wash down conditions, TEFC design and inverter rated.
8) Blowers shall have a variable flow output designed to run in concert with an automated variable air
flow control system, providing air as required in the aeration tanks based on oxygen demand. The system
shall include, as minimum:
• PLC based local control panel at each blower with visual touch screen HMI including safety shut
downs (i.e. motor thermistor, surge control if necessary etc.);
• PLC based master control panel with visual touch screen HMI including automated DO control and
flow and pressure optimization through most-open valve algorithm;
9) All blower sets shall be fitted with the following ancillaries:
• Discharge pressure relief valve – set to 10% above system operating pressure and capable of 100%
blower discharge flow, with an accumulation not in excess of 10% of set pressure;
• Discharge check valve;
• Pressure gauge;
• High discharge air temperature switch, to signal shut down of problem machine and auto start
standby unit.
• Anti-vibration pads and inlet/discharge flexible connections of the expandable SS corrugated/

bellows type.
• Inlet silencer – absorptive type with filter rated for 20% above design flow;
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• Discharge silencer – reactive type – for all applications and sized to ensure minimal pressure loss;
• Blower discharge piping shall be fitted with an after cooler designed to lower the temperature of
the blower discharge air to equal the approximate ambient temperature of the wastewater in the aeration
process.
• Inlet/Outlet isolation valves; and
• For centrifugal type blowers, a vibration sensor to monitor and automatically shut down the
equipment if necessary.
10) Standards/Norms - Compressor testing procedures, as well as the testing equipment,

instrumentation, and calibration are based on national and international standards as follows:
• ISO 5389: International standard: Turbo compressors - Performance Test Code
• ISO 5167: International standard: Measurement of Fluid Flow.
• ISO 10816-1: Mechanical Vibration of Machines.
• ISO 3744: Determination of Sound Power Levels of Noise Sources.
• ISO 3746: If free-field conditions cannot be established ISO3746 will apply.
• API Standard
• 672/4.3.4.1: Packaged, Integrally Geared Centrifugal Air Compressors for General Refinery
Service
10) High speed centrifugral blower or turbo blower shall be acceptable for high efficiency and low
electricity consumption
8.3 Compressors
Compressed air equipment shall be capable of continuous automatic operation and shall require the
minimum of maintenance.
Air compressors shall be in accordance BS 7316:1990 and capable of delivering dry oil and particulate free
air at the volume and pressure required.
The compressor performance shall be in accordance with IS 5456:2006, BS ISO 1217:2009, BS 1571-
2:1975.
The compressor units shall include air cooled compressors, motors, pressure switches, gauges with pressure
snubbers and isolating cocks, pressure tanks with hand holes, relief valves, drain cocks from tanks with
pipes taken to the nearest gully, line pressure regulators, oil separators and all other necessary controls,
pipework etc.
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The compressor shall have suction filters, suction and discharge silencers and be mounted on vibration
isolators on a common rigid mild steel base plate on top of the receiver. The pipework connections to the
compressors shall be flexible to avoid vibrations being transferred to the pipes or to any structures.
8.4 Aspirator aerators
In Facilities where it is applicable, the unit supplied must be able to operate both in mixing and in aeration
mode controlled completely independently of each other. Unit must have two distinct modes of operation;
simultaneous aeration and mixing mode, and mixing only mode. The aerator consists of an electric motor
and regenerative blower located above the water surface. The motor is connected to a hollow shaft with a
protective housing positioned at a 45° angle downward into the water.
Aerators with submersible motors are not acceptable. The hollow shaft drives a mixing propeller and saturn
ring-type diffuser beneath the water surface. Attached to the primary propeller is a Saturn ring diffuser,
which disperses the air as fine bubbles (2.0-2.5 mm diameter) into the stream of displaced water beneath
the water surface.
8.5 Diffuser
In Facilities where it is applicable, the aeration system may be provided to meet the aeration requirement
as per the process design requirement. Sufficient design calculations are to be provided along with
manufacturer standard having supplied diffuser during last five years to various waste water treatment
plants.
8.6 Fine bubble aeration system
In Facilities where it is applicable, the membrane diffuser shall be developed specifically for releases
1~3mm fine bubble in the wastewater treatment plant. All materials have been selected for their ability to
withstand the effects of the chemical, bio-chemical agents and 0~50°C used in wastewater tank. The
diffuser can be placed in an evenly distributed grid system over the entire aeration tank bottom.
Diffuser grid shall be of fixed or retrievable type. Diffuser shall be Tubular/Disc type with membrane made
of Polyurathene/silicon elastomer. It shall have PVC diffusers holder with retainer rings. Maximum air
throughput from diffusers shall be restricted to 90 Nm3/hr/m2 of membrane area. For all types of grid,
supports, frames, anchors and all other steel components shall be in SS 304. The aeration system shall
include air distribution purge system.
9. Decanters for SBR

In Facilities where it is applicable, SBR decanters shall be floating or electromechanically positioned with
subsurface withdrawal and a positive solids and scum exclusion mechanism. Each decanter shall be capable
of withdrawing decant effluent from 4 to 6 inches beneath the liquid surface, regardless of liquid depth,
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down to minimum operating design level. Decanters shall employ positive mechanical seals or substantially
similar mechanisms for excluding solids, scum and any floating matter.
Site fabrication of decanters shall not be acceptable.
A telescopic valve arrangement shall be provided in each basin for periodic removal of scum and floating
material. For electromechanically positioned decanters, the decant of each phase shall be preceded by a
skimming phase that shall fully and completely remove all scum and floating material.
All wetted components of decanter assembly shall be of SS 316 L Stainless Steel. The decanters shall be
designed to mount to an approximately sized cement motar lined and coal tar epoxy coated ductile iron
flanged pipe embedded in SBR basin wall. The wall pipe and embedment shall be designed to safely
accommodate all loads transmitted by decanter assembly under all operating and maintenance conditions.
10. Gravity sludge thickener

In Facilities where it is applicable, Gravity sludge thickener shall be circular (radial), fixed bridge, central
turn table type or central drive. Concessionaire may also provide alternatively the mechanical sludge
thickener. The sludge thickener mechanism shall be suitable for installation in a circular RCC tank and
shall include the following:
• Mechanism support beam spanning the diameter of the tank.
• Walkway and handrail from the edge to the centre of the tank. Clear walkway should be provided
as per standard engineering practice.
• Drive mechanism with internal gear type.
• Reduction gear box.
• Chain and sprocket with guard.
• Central shaft with scrapper arm and picket fence.
• Skimmer scum baffle and scum trough.
• Overflow weir:
• Vertical pickets.
• Torque indicating device.
• Overload alarm protection.
• Auto lifting device.
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The minimum thickness of all the underwater parts shall be minimum 6mm thick excluding allowance for
corrosion.
Material of Construction
Tank : Reinforced Cement Concrete
Feed Well : SS 304, 6 mm thick minimum
Bridge : MS with hot dip galvanized (galvanizing minimum thickness
shall be 80 micron)
Center Cage : Mild Steel Galvanised
V-notch weir : SS 304 or, minimum 6 mm thick and
Squeegees : Neoprene
Handrail : 40 NB MS Pipe with Hot Dip Galvanised (radial upto centre)
Anchor Bolt & fasteners:Stainless Steel -316
Walk way : MS with Hot dip Galvanized (galvanizing minimum thickness shall be
80 micron), 6 mm thick chequered plate, 1200 mm wide
10.1 Sludge Rotary Drum Thickeners
Drum thickeners shall comprise continuous flow, polymer enhanced; gravity settled sludge process
incorporating a slowly rotating inclined drum incorporating a perforated screen or filter arrangement,
enclosed in a housing and pre-mounted on a self-contained skid/frame.
The rotary drum thickener shall be capable of thickening an input sludge of 0.5% dry solids (DS) to a final
thickened sludge of 8% DS.
All wetted parts in contact with the sludge or moisture shall be made of 316L stainless steel. The drum
thickener shall be pre-mounted on a self-contained skid support arrangement.
The drive system shall include an electric variable speed drive motor suitable for outdoor wet weather and
wash down conditions, TEFC and an enclosed gear reducer unit (oil bath type).
The perforated screen or filter element may be manufactured from316L stainless steel or polyester, suitably
reinforced for the intended purpose and pressures involved.
The entire drum assembly shall be adjustable for angle of tilt. A gauge shall be fitted to the side of each
drum casing and shall display the selected tilt angle.
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The rotating drum shall be mounted on self-lubricating bearings.
The sludge inlet shall include a specially designed sludge/polymer conditioning (mixing / blending)
apparatus.
Filtrate liquid shall be collected in a through beneath the rotating drum. The trough shall be equipped with
a filtrate outlet pipe which shall incorporate sampling and cleaning points.
Washing systems: The perforated screen or filter element shall be washed with a medium pressure spray
nozzle system to clean the screen and remove any sludge sticking to the internal surface. The wash water
shall be collected on a trough and blended/mixed with the filtrate liquid removal system.
The thickened sludge shall be discharged at the high end of the unit onto an inclined collection chute. The
chute shall be made of 316L stainless steel highly polished top surface or coated with Teflon.
The drum thickener shall be provided with an enclosure housing designed to reduce the release of odours.
The housing shall be equipped with removable maintenance panels and high viewing windows. A viewing
window shall be provided at the discharge end of the drum for monitoring of the sludge thickening process.
The viewing window shall be safe to open during operation and shall be made of shatter-proof
thermoplastic. Maintenance access shall be provided at the sludge discharge end.
A local control panel shall be provided to control all associated equipment, including: the sludge feed
pumping, polymer feed system, any discharge conveyor system etc.
Thickeners shall be provided with a common pre-designed polymer make-up system, pre-mounted on skids,
incorporating, as a minimum, a dry polymer loading and hopper system, a dry polymer / water flush mixing
/ blending system, mixing tank, transfer pumps, piping system, storage tanks, individual dosing pumps,
metering and controls, etc.
11. Gas generating set & accessories

The gas generators, installed by the Concessionaire, shall be designed with standby unit(s) to operate at
maximum gas generation.
The bio gas will have concentration of H2S @ 1.5% to 2.0%. This H2S which is highly corrosive in nature
has to be removed from the sewage gas before storage. This H2S has to be removed from this sewage gas
by using chemical gas cleaning scrubbers.The H2S content in the sewage gas generated shall be removed
by a H2S scrubbing system. The scrubber shall be capable to reduce the concentration below 200
ppm/required level.
• Gas holder
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In Facilities where it is applicable, the gas holder shall have a holding capacity as per CPHEEO. The gas
storage shall maintain a maximum gas pressure of 250 mm WC/wg. All gas holders shall be provided with
the gas safety equipment (dual pressure relief/vacuum devices) as specified herein for protection of the
storage unit.
• Bio gas scrubbing system
The system (1W+1S) shall include major equipment like Pre-Scrubber, Scrubber, wash tower, regenerator,
filter press and pumps. The system should be with zero liquid discharge and no gases/ effluent emission in
the process of scrubbing.
• Flare system
a) A Comprehensive auto flare philosophy shall be adopted. Gas flow on the gas flare line shall have
interlock with the flame detector to conclude the effective flaring.
b) The flare unit shall be designed for biogas flow generated during average flow conditions. It shall
be fabricated of suitable materials (carbon steel except for top portion which shall be in SS 304). The design
of flare unit will be such that it shall be conveniently mounted on the steel supporting structure.
c) The velocity of biogas through the flare unit should be minimal considering 100-150 mm WC
pressure of biogas at flare inlet. Capacity of Gas flare system shall be provided for total gas generated from
the proposed plant. Gas from existing plant is not to be considered. Gas flare system shall be one working
and one standby unit along with all accessories. Burner capacity shall be 150% of design gas generation.
d) A suitable spark ignition system should be provided at a convenient location. Biogas shall be used
as a pilot fuel. The pilot flame generated with the help of spark ignition systems shall propagate through
the flare unit to ignite main biogas. The control system involving control panel, ignition transformer etc.
shall be provided for the said purpose.
e) H.T. cable shall be provided from the secondary terminal of ignition transformer up to spark
ignition system. Necessary ignition electrode OR 1 number 25 KVA generator set shall be provided. The
25 KVA generator set can also be used to start the gas engine.
• Moisture trap
The moisture trap shall be designed to effectively separate out moisture in the biogas such that moisture
free biogas is made available at the outlet of a trap. It shall be of suitable materials of construction and be
provided with suitable drain connection.
• Flame trap
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a) The flame trap shall be of suitable size for biogas application. It shall be used primarily in pipe
lines to prevent flash back during explosions.
b) This device shall be installed in horizontal or vertical pipe line and hence it should be
bidirectional.
c) The flame arresting element shall be designed such that it results in minimal pressure loss under
normal operating condition but to ensure maximum security in the event of explosion, the end connection
shall be flanged.
12. Sludge dewatering units

In Facilities where it is applicable, sludge dewatering shall be done by mechanical sludge dewatering units
such as Solid Bowl Centrifuge, Belt Filter Press. The material of construction shall be SS 316. The
dewatering units shall include but not limited to the following equipments:
Powder or liquid polymer storage tanks/ bach tanks with mixers, polymer metering pumps, mixers and
solution tanks, supply line & flush line, plant water supply pumps, sludge feeding pumps, dewatering unit,
cake hopper, control valves on sludge feeding line, and on chemical feeding line, drain system.
The dewatering system should be so located that the dewatered sludge can be loaded into trolleys/ drums/
bins directly – preferably the dewatering unit shall be so located that the dewatered sludge falls into the
containers/ bins without requirement of another material handling unit.
The dewatered sludge should be truck-able & be suitable for disposal by open body truck and should have
a minimum solid concentration of 20% or more (measured as dry solids w/w basis).
The dewatering unit should have a 95% solid recovery. Dewatering units shall be provided in a separate
sludge dewatering building. Feed pump station shall be provided at lower level/floor and dewatering units
shall be provided at upper level/ floor.
13. Pumps
In Facilities where it is applicable, the following specifications would be applicable to pumps.
A. Sump Pump
• The pumps shall run smooth without undue noise and vibration.
• The power rating of the pump motor shall not be less than the maximum power required from
zero discharge to zero head.
• Pump should be vertical, centrifugal, single stage, non-clog type.
• It should be suitable for handling sewage containing stringy materials.
• Plate type strainer should be provided to prevent large size solids entering into pump
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• The pump shaft journal bearings shall preferably be grease lubricated. No external water will be
made available for the lubrication of the bearings.
• Delivery piping with gun metal non-return valve should be supplied.
• Delivery pipe should be as per IS: 1239, medium class.
• Pump should be operated automatically by providing float operated level switch .
• The base plate shall not be directly fixed to the floor. Channels should be grouted in the floor and
the base plate should be attached to the channel.
Materials of Construction
a. Impeller : Duplex Stainless steel CD3MCuN
(Choromium 24% minimum, carbon ≤ 0.3 %) as per
ASTM A890 Gr 1C or DIN 1.4517-EN 10088,
Hardness 220-260 BHN/ Stain less Steel (CF 8M)
b. Casing : Cast Iron FG260 as per IS 210 with 2% NI
c. Shaft : Stainless steel
d. Cover plate : Steel
B. Submersible pumps
Design requirements
1. Submersible pumps shall be submersible, vertical shaped, centrifugal, non-clog type, suitable for
municipal sewage, design for continuous operation in submerged / partially submerged condition
and intermittent operation complete with motor control system, guide rail, anchoring brackets, base
elbow, power cable & pumping lifting cable/ SS chain with control panel and level transmitters
suitable for solid passage of 100mm diameter and above.
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2. The efficiency of the pump shall be high at duty point and remain reasonably high during the full
duty range at the pumping system.
3. The pump shall be compatible with VFD and selected automation system.
4. The pump should be capable of developing the required total head at rated capacity. Pumps
should be suitable for single as well as parallel operation at any point.
5. The pump should deliver at least 125% of its rated capacity at 75% of the specified total head.
The H and Q curve should be continuously rising towards shut off head.
6. Pump charecteristics shall be non-overloading for the entire range of operation of the pump.
7. The velocity of vibration should be less than 4.5mm/ sec. with noise level 85 dBA at resistance of
1.85 meter.
8. The power rating of the pump motor should be the larger of the following:
a. The maximum power required by the pump from zero discharge to zero head.
b. Power required at the duty point with margin as per CPHEEO manual at duty point considering
the combined efficiency (motor & pump).
9. The combined efficiency of the pumps, for IPS and MPS shall not be less than 65%. The motor
efficiency shall be comparable to IE3 efficiency class. The highest efficient pump set shall be considered
for selection.
10. Submission of pump data sheet shall be tagged as variable frequency drive/normal operation.
11. MPS/IPS pumps will have provision for shredding of fibrous material in/before the impeller to
avoid clogging due to the same.12. Material of Construction
a) Pump casing : Cast Iron FG260 as per IS 210 with 2% NI
b) Impeller : Preferably Duplex Stainless steel CD3MCuN
(Choromium 24% minimum, carbon ≤ 0.3 %) as per
ASTM A890 Gr 1C or DIN 1.4517-EN 10088,
Hardness 220-260 BHN/ Stainless steel (CF8M)
c) Shaft : Stainless steel 410
d) Bearing Bracket : Grey cast iron (CI IS: 210FG260)
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e) Motor casing : Grey cast iron (CI IS: 210FG260) with 2% Ni
f) Bolts, nuts : SS316
g) Shaft protective sleeve : SS316
h) Casing wear ring : Preferably Duplex Stainless steel
CD3MCuN (Choromium 24% minimum, carbon ≤ 0.3 %)
Its hardness to be 50 BHN less than impeller hardness/ Grey Cast Iron
FG260 as per IS 210.
i) O-ring : Nitrile rubber (NBR)
j) Shaft seal
Type of seal : Double mechanical seal
Arrangement : Tandem
Seal on medium side : With elastomer bellows
Mechanical seal, pump side : Silicon carbide
Mechanical seal, bearing side : Carbon/ silicon carbide
k) Monitoring
Thermal winding protection : Thermistors PT-100 in all three phase winding
Explosion proof protection
Motor housing monitoring : By conductive moisture sensor electrode
Mechanical seal leakage detection : By float switch
Bearing temp monitoring : Thermistors PT 100 in upper bearing
l) Installation
• Type of installation : wet well installation design for automatic connection
to a permanently installed discharge elbow will
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neoprene seal to avoid metal to metal contact
• Flange dimension to : EN 1092-2, / IS 1538/suitable for flanges of fittings &
Piping
• Claw : Bolted to the pump
• Installation depth : As per data provided
• Guide system : Stainless Steel
• Lifting device : Stainless steel lifting chain
• Length of lifting device : Suitable
• Lifting loops : suitable
• Installation accessories : Discharge elbow, fasteners, claw, bracket, lifting

chain, guide bars etc. complete
m) Motor
• Degree of protection : IP 68
• Insulation class : F
• Coolant temp : </= 40 C
• Starting mode : Direct
• Rated voltage : 3ph, 415 V
• Rated freq : 50 Hz
• Nominal speed : Less than 1500- rpm (Synchronise)/1000 rpm preferably
• Voltage tolerance : ±10%
• Motor casing : Grey cast iron
• Main cable : complete with cable length as per requirement
C. Mixed Liquor Pumps
Type of Pump Vertical Propeller Tube Type
Type of fabrication Self-Water
RPM 590
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Pump Efficiency Min. 75%
Motor Efficiency IE3
Pump housing 2% NiCI FG260 as per IS 210
Impeller
SS316 (CF8M)
Pump Shaft Stainless steel 410
Discharge Head Steel Fabricated
Motor Cast iron, EN-JL1040, AISI A48 30
Voltage 415 ±10% 3 Phase
Frequency 50HZ
Note: 1. The Pumps will have VFD.
D. Horizontal centrifugal pumps
Design requirements:
a. The pump should be capable of developing the required total head at rated capacity. Pumps should
be suitable for single as well as parallel efficient operation at any point in between the minimum and
maximum system resistance indicated in the system resistance curves.
b. The total head capacity curve should be continuously rising towards the shut off. The pump should
deliver at least 125% of its rated capacity at 75% of the specified total head.
c. In the operation range of the pump, NPSHr<NPSHa with sufficient margin as per applicable
codes/guidelines.
d. Pumps shall run smooth without undue noise and vibration. The velocity of vibration should be
within 4.5 mm/sec. The noise level should be limited to 85 dBA at a distance of 1.85 M.
e. Pump charecteristics shall be non-overloading for the entire range of operation of the pump.
f. The power rating of the pump motor should be the larger of the following:
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i) The maximum power required by the pump from zero discharge to zero head.
ii) Power required with margin as per CPHEEO manual at the duty point considering the
combined efficiency of pump and motor with zero negative tolerance.
g. The pump set should be suitable for starting with discharge valve open, as well as closed.
h. MPS/IPS pumps will have provision for shredding of fibrous material in/before the impeller to
avoid clogging due to the same.
Features of construction
a. Pump should be suitable for applications in municipal sewage handling or sludge handling as per
process requirement, with back pull out design. It shall have end suction and side discharge. It should be of
self-venting type.
b. Pumps should be identical for particular application and suitable for parallel operation with equal
load division. Components of identical pumps should be interchangeable.
c. Pump casing should be of robust construction Liquid passages should be finished smooth and
designed so as to allow free passage of solids. The volute tongue should be straight across and filed to a
smooth rounded edge. Casing should be provided with hardened renewable wearing ring.
d. Impeller should be suitable for application, semi open non clog type smooth blunt edges and large
water ways so as to allow free passage of large size solids. It should be free from sharp corners and
projections likely to catch and hold rags and stringy materials. Impellers should be provided with hardened
wearing ring. Hardness of the Impeller ring should be at least 50 BHN more than that of casing ring.
e. The first critical speed of the rotor should be 30% above the operating speed. Complete
rotor should be statically and dynamically balanced.
f. Replaceable shaft sleeves should be provided to protect the shaft where it passes through stuffing
boxes. Surface hardness of shaft sleeve should be minimum 700 BHN.
g. Pumps should be provided with anti-friction bearings. Bearings should be easily accessible for
inspection and maintenance. Bearings should be grease lubricated.
h. Stuffing box should be of such design that they can be repacked without removing any part other
than gland and lantern ring. Stuffing box drain with pipe connection should be provided at the lowest point
so that no leakage accumulates in it.
i. Lantern ring should be of axially split type. Grease should be used for stuffing box sealing. Water
will not be available for this purpose. Gland should be of split type.
j. Pump should be furnished complete with flexible coupling.
k. Coupling guard bolted to the base plate should be furnished.
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l. Base plate for pump and motor should be common. Suitable holes should be provided for grouting.
Foundation bolts should be complete with nuts and washers.
m. Tapping should be provided at suction and discharge nozzles for pressure gauge connection.
n. Hand holes should be provided in the casing to allow easy access to the impeller as well as to the
casing throat. Casing drain connection with stainless steel collared plug should be provided.
a. Casing :
2% NICI with Hardness 275 BHN with suitable coating inside casing of
500 micron DFT, suitable for protection against corrosion,
erosion and prevent oxidation.
b. Impeller : Duplex stainless steel CD3MCuN
(Choromium 24% minimum, carbon ≤ 0.3 %) as per ASTM A890 Gr 1C or
DIN 1.4517-EN 10088, Hardness 220-260 BHN
c. Wearing rings : Duplex Stainless steel
CD3MCuN (Choromium 24% minimum, carbon ≤ 0.3 %)
Its hardness to be 50 BHN less than impeller hardness.
d. Shaft : Stainless steel 410
e. Shaft sleeves : Stainless steel withceramic
coating, hardness 700 BHN min
f. Packing : Asbestos yarn coated with MoS2 (Molybdenum Di-Sulphide)
g. Packing : CI/MS fabricated.CI IS210 Gr F G260
h. Base plate : CI/MS fabricated IS 2062
i. Gland : Cast Iron CI IS 210 Gr F G260
j. Coupling : CI
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E. Dewatering pump
a. Pump should be suitable for handling settled sewage containing grit and suspended particles.
b. The pump motor should be suitable for working with or without submergence in sewage. The
motor rating should be more than the maximum power required by the pump.
c. The pump set should be portable with necessary hooks.
d. The pump should be suitable for dewatering from a pit 900mm x 900mm x 100mm deep.
e. The pump should be vertical, centrifugal, non-clog type.
f. The pump impeller should be mounted on the extended shaft of the motor.
g. The pump should be provided with mechanical seal.
h. The pump should be supplied with flexible hose pipe of 50mm, 50M length.
i. Suitable cable of 50 M length should be supplied with the pump.
Materials of Construction :
a) Impeller : Stainless Steel
b) Casing : Cast Iron AS PER IS 210 GRADE F260
c) Shaft : EN8 (as per IS: 970)
F. Progressive cavity pumps
The progressive cavity pumps shall be self-priming and designed to handle abrasive, shear sensitive and
viscous materials, solids in suspension and liquid/solids mixtures.
Automatic Variable stroke frequency / stroke length arrangement shall be incorporated wherever remote
application with PLC/SCADA is envisaged and process demands these changes through remote, Local
Control Panel shall also be envisaged with each pump with auto/manual selector switch and knob for these
variations done manually.
The sludge will be a mixture of grit in the sludge that will be abrasive. The pump design shall incorporate
features that prevents ragging around pump connecting rod and rotor head and include a shaft sleeve to
protect the wear in these highly abrasive environments. These conditions must be considered when selecting
the pump. Pump should be screw type, slow speed maximum 200 rpm having following construction
features:
Casing : CI IS 210-FG 260
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Rotor : SS316 Hard Chromed plated
Base Frame : ISMC Fabricated Epoxy coated
Bearing Housing : CI IS 210-FG 260
Shaft : SS 316
Foundation bolt : HTS GALVANIZED STEEL
Stator : Hypalon/Equivalent linning
Coupling : Flexible pin bush type
Coupling guard : MS Fabricated
The pumps must be sourced from a supplier that is ISO 9001:2000 certified to ensure that the pump is
manufactured to certified standards.
14. Polyelectrolyte solution preparation and dosing system

Polyelectrolyte solution is needed to be prepared and dosed for aiding sludge thickening and dewatering.
The polyelectrolyte will be dosed online at the centrifuge inlet. Minimum dosage of polyelectrolyte shall
be worked out by the Concessionaire. There shall be two poly-dosing tanks each suitable for minimum 8
hrs. of operation. Each-tank shall be equipped with slow speed mixer (100 RPM) to prepare polyelectrolyte
solution. The solution will be fed using positive displacement metering type dosing pumps. There shall be
dedicated dosing pumps to each centrifuge with one common standby. The pumps shall be interlocked with
centrifuge so that it can only be running in auto when centrifuge is on and should shut down when centrifuge
stops. The dosing system shall be housed in centrifuge house itself.
The polymer dosing required shall be as per design requirement. Polymer dosing pumps hydraulically
actuated diaphragm pumps simplex and duplex type with maximum injection pressure of 5 kg/cm2
complete with PP head, PP / PVC fittings, strainer, inbuilt PRV along with 415 V / 50 C / S suitable motor
at 1000 RPM are required. The system will also have storage bins, polymer batch tank and polymer batch
tank mixers.
14.1 Dosing pumps
The dosing pumps shall be selected to achieve optimum dosing technology and control safety with safety
relieve valve. The pump shall have a resistant plastic enclosure that can safely be used for the selected
application and shall provide soft and low-pulsation dosing.
The pump shall incorporate sensitive sensors that monitor the dosing flow and the diaphragm and provide
process stability. The pumps shall be designed to have separation of hydraulics and electronics, to
protected process from equipment failure.
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Diaphram Valve, Gasket : PTTE
Liquid End : Stainless Steen 316
Foundation Bolt : Mild Sleet Epoxy Paint
Wetted Part : SS 316
Base Frame : Carbon Steel, epoxy Painted.
Flanges : Carbon steel
Plunger : Carbon Steel
Accuracy : ±3%
Voltage : 415 ±10%
RPM : 1440
15. Dismantling Joints

Where dismantling joints, flexible couplings or flange adaptors are used these shall be of the Viking-
Johnson type except where otherwise specified or approved. Pressure ratings shall match the pressure rating
of the pipework in which they are installed, and materials used and methods of protection shall not be
inferior to those used for the pipework. Where needed, joints and couplings shall be provided with tie bolts
to restrain the maximum axial thrust arising when in service.
The dismantling joints for ductile iron pipes shall be of ductle iron with EPDM seal ring.
16. Valves
 General
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(a) Valves shall be as per internationally recognised standards. Flanges shall be machined
on faces and edges and conform to ISO 7005, IS 6392 or BS 4504.
(b) Valves shall be double flanged type and the face shall be parallel to each other and flange
face should be at right angles to the valve centreline. Back side of valve flanges shall be machined or
spot faced for proper seating of the head and nut.
• (c) Valve buried or installed in underground chamber, where access to a handwheel would be
impractical shall be operated by means of extension spindle and / or keys.
• (d) Valve of diameter 450 mm. and above shall be provided with lifting eyes and shall have
detachable bolted covers for inspection, cleaning and servicing.
• (e) Valve shall be suitable for frequent operation as well as operation after long periods of
idleness in either open or closed position.
• (f) The valve stem, thrust washers, screws, nuts and all other components exposed to the
water shall be of a corrosion resistant grade of stainless steel.
• (g) Valves shall be free from sharp projections.
A. Sluice valves
Sluice valves shall be generally conforming to IS: 14846:2000. Additionally they should meet the specific
requirement given below. The valves shall be double flanged machined and drilled to IS-1538 Part IV &
VI.
General
1. Sluice valve shall be conforming to IS: 14846: 2000 and with ISI marking. Additionally they
should meet the specific requirement given here under.
2. Sluice valve must be from ISO-9001 certified company towards Quality Management System.
3. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The back side of
the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable clearance behind the rear
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face of the flange on body and bonnet to be kept to provide free access to use spanners for assembling &
dismantling. No tap hole is acceptable.
1. Body : Cast Iron to IS: 210 Gr. FG200
2. Wedge : Cast Iron to IS: 210 Gr. FG200
3. Spindle : St. Steel to IS: 6603 04Cr18Ni10
4. Seat Rings : SS to CF8
5. Spindle Nut : High Tensile Brass to IS – 320 HT2
6. Back Seat Bush : SS to CF8
7. Shoe & Channel Lining : SS to CF8
Shop Testing Witnessing
1. Seat Leakage Test (2 Minutes) : 10Kg/cm2
2. Body Leakage Test (5 Minutes) : 15Kg/cm2
3. Back Seat Leakage Test (2 Minutes) : 10Kg/cm2
B. Check valve
1. Checking valve shall be conforming to IS: 5312. Additionally they should meet the specific
requirement given below.
2. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The backside of
the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable clearance behind the rear
face of the flange on body to be kept to provide free access to use spanners for assembling & dismantling.
No tap hole is acceptable.
a. Body & Cover : Cast Iron IS: 210 Gr. FG 260
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b. Door : Cast Iron IS: 210 Gr. FG 200
c. Hinge Pin : St. Steel to AISI – 316
d. Seat Rings : Gunmetal with 2% Nickel / IS: 318 Gr. LT B2
e. Bearing Bush : Teflon
f. Fastener : carbon steel
Shop Testing Witnessing
1. Seat Leakage Test (2 Minutes) : 10Kg/cm2
2. Body Leakage Test (5 Minutes) : 15Kg/cm2
C. Kinetic air valve
General
1. Kinetic air valves shall be conforming to IS: 14845: 2000. Additionally they should meet the
specific requirement given here under.
2. Kinetic air valves should be from ISO – 9001 certified company
3. The valves shall be flanged end machined and drilled to IS – 1538 Part 4 & 6
Body, Cover, Cowl : Grey Cast Iron. IS: 210 – 1993 Gr. – 260
Ball of small orifice : Seasoned timber ball covered with soft Vulcanite
Ball of large orifice : Seasoned timber ball covered with soft Vulcanite
Seat of large orifice : Neoprene Rubber
Nipple for small orifice : LT : IS 318 – 1980. LTB – 2./ AISI: 410
Isolating Gate valve : IS: 14846 (GM internals & AISI: 410 Spindle)
Bolt & Nut : M.S
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Shop testing witnessing
Seat & body leakage test (2 Minutes) : 10Kg/cm2
Painting & coating
Pre – inspection
1st Step Surface preparation
Blast cleaning to near white – SA 2 ½ Gr.
2nd step Application of primer coating after blast cleaning
One coat of two component epoxy based primer
Post – inspection, if applicable
3rd Step Application of finish coat
One coat of two component solvent free amine cured epoxy coating (shade)
D. Butterfly valves
Unless otherwise specified, valve body and disc shall be of close-grained gray cast iron. Valves shall
be mounted with shafts horizontal or vertical based on manufacturers design. Valves shall be fitted with
indicators to show the position of the disc, clearly marked with ‘open’ and ‘closed’ positions. Valves shall
not contain any brasses containing more than 5% zinc. Gunmetal conforming to BS 1400 Grade LG2,
aluminum bronze, or nickel components may be used for internal components. Resilient-seated valves shall
have nitrile rubber seals.
For valves of 900mm and above, retaining rings shall be provided to enable the sealing ring to be
replaced without the need to remove the valve body from the pipe work. Metal seated valves of 900mm and
above, shall have seat clearances adjustable to obtain as near a watertight condition as possible, without the
need to remove the valve body from the pipe work.
Percentage Opening - Flow Curve shall be submitted along with data sheet mentioning area where such
valves are subjected for any controlling of the fluid flow.
Component Material
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1 Body Cast Iron : IS:210 Gr FG260
2 Inner lining Stainless steel : BS:970 Gr 304
3 Plate /DLSC Stainless steel : IS 3444 1987
4 Stem Stainless steel : IS 6603:1972
5 Seat ring / Boss Stainless steel : IS 6603:1972
6 Gland housing Cast Iron : IS:210 Gr FG260
8 Gland packing Teflon Impregnated with asbestos+Rubber
E. Pressure-Relief Valves (PRV)
Pressure-relief valves shall be designed to prevent the pressure in the pipeline upstream of the valve rising
above a preset level. The valve shall remain closed at lower pressures. The pressure at which the valve
opens shall be adjustable. A pressure gauge shall be provided to indicate upstream pressure over the
operating range of the valve. Safety valves shall comply with BS 6759: Part 1.
They shall be designed to open at the specified pressure and re-close and prevent further release of fluid
after normal pressure has been restored. The pressure / temperature rating shall be in accordance with
relevant standards. Flanged ends shall be Class 900, raised-face type complying with ANSI B16.25 or
relevant standards.
Component material
3 Knife gate/ plate Stainless steel : BS:970 Gr 304
4 Stem Stainless steel : BS:970 Gr 304
5 Seat ring / Boss Stainless steel : BS:970 Gr 304
F. Ball valves
Ball valves shall conform where applicable to relevant standards. Multi-piece bodies shall be used where
work on the ball and seats when installed may be needed. If valves need removal for servicing, one-piece
bodies may be used. Seat materials shall be chosen for long life, with erosion and corrosion resistance. Ball
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supports shall be of the floating ball or trunnion type. If line pressure is too low to ensure a positive leak-
free seal, built-in seat loading devices, or specially shaped seatings shall be used to ensure sealing.
Component material
3 Plate Stainless steel : BS:970 Gr 304
4 Stem Stainless steel : BS:970 Gr 304
5 Seat ring / Boss Stainless steel : BS:970 Gr 304
G. Knife gate valves
The valve shall meet standards C105/A21.5-10, C520-10, C706-10, C707-10, C713-10 and D106-
10 and testing requirements of MSS SP 81.
Outer body may preferably be provided with inner liner in corrosion resistant stainless steel which
shall extend into the gland. The body shall be devoid of any wedge/ dead pockets to avoid setting of
suspended particles and solids in the service fluid.
The gate / plate shall be precision buffed and the edge contoured to a knife edge. The gate shall
move along / be guided by the seat ring to ensure that it scraps any deposit / scale enabling smooth
uninterrupted movement.
Seat shall be so designed that there is no recess / relieve groove to harbour deposition that could
build-up and swamp the valve. The design should also incorporate bosses that guide the gate and avoid
deflection ensuring positive shut-off. The stem shall have double start threads cut in order to ensure smooth
and speedy operation.
Gland packing shall offer minimal frictional resistance and precludes external lubrication. As
positive sealing elements, the packing shall also include a resilient rubber ring. The knife edge and seat face
in flow path shall be hard faced to a hardness of 400 to 450 BHN to counter erosion. In such cases, provision
shall also be made to ensure the fluid contact with the seat ring is minimal.
Component Material
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1 Body – Cast Iron : IS:210 Gr FG260
2 Knife gate/ plate – Stainless steel : BS:970 Gr 304
3 Stem – Stainless steel : BS:970 Gr 304
4 Seat ring / Boss – Stainless steel : BS:970 Gr 304
5 Gland housing – Cast Iron : IS:210 Gr FG260
6 Gland packing – Teflon Impregnated with asbestos + Rubber
H. CI flap valves (circular flap valves)
The flap valves with circular aperture, single door and double flanges, shall be provided. The flap valves
upto 600mm dia shall have sealing faces in angular section and secured to the frame and door by a force
fit. For sizes above 700 to 2000mm dia the sealing faces are of rectangular section and are secured to the
frame and door using countersunk taper headed screws in the same material as the sealing face. The flap
valve shall be suitable for mounting on a vertical wall or flange for static seating heads up to 6 meters.
Material of specification
Frame
Constructed in BS EN 1561 min. 250 cast iron designed for wall, thimble or pipe mounting applications.
Door
Constructed in BS EN 1561 min. 250 cast iron designed to withstand static seating heads up to 6 meters.
Sealing Faces
Copper alloy sealing faces to BS EN 1982 : 1999 are supplied as the standard material for ranges up to
600mm dia and for the ranges 700 to 2000mm dia phosphor bronze to BS EN 12167 : 1998. Sealing faces
are set to 0.1mm feeler gauge non-acceptance to provide an effective seal.
Hinge Links
Manufactured in Spheroidal Graphite cast iron
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Fasteners
Standard fasteners are supplied in stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).
Hinge Pins
Manufactured from stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).
17. Sluice gates
If applicable in a Facility, sluice gate shall be preferably wall thimble type. The construction of sluice
gates shall be in accordance specification and generally to IS:13349.
The materials of construction of important components of gates will be as under:
a. Frame & Shutter Cast Iron IS: 210 Gr. FG 200
b. Wall Thimble Cast Iron IS: 210 Gr. FG 200
c. Seating Faces & Counter Sunk Fixing Stainless Steel ASTM A276 type 316
d. Wedging Device Cast Iron IS: 210 Gr. FG 200
e. Wedge Linings Stainless Steel ASTM A276 type 316
f. Stem & Stem Coupling Stainless Steel ASTM A276 type 316
g. Stem Nut Stainless Steel ASTM A743 CF8M or SS316
h. Flush Bottom Rubber Seal EPDM ASTM D200
i. Seal retainer bar Stainless Steel ASTM A276 type 316
j. Fasteners, Studs Anchor Bolt & Nuts Stainless Steel ASTM A276 type 316
k. Lift Nut Bronze IS: 318 Type LTB-2
l. Headstock, Stem Guide Cast Iron IS: 210 Gr. FG 200
m. Hand wheel Mild Steel IS: 2062
n. Painting Ordinary Black Bituminous Paint
18. Actuators:
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All the valves shall be operated by an electro mechanical actuator, comprising of motorized gear train
and screw assembly which drives the valve stem. The actuator shall be supplied with the following
accessories.
3 phases, 415 V, + 10%, 50 Hz. + 5%, A.C. squirrel cage induction motor.
Reduction gear unit.
Torque switch mechanism complete with set of torque switches.
Limit switch mechanism complete with set of limit switches.
Hand wheel for manual operation.
Hand-auto changeover lever with suitable locking arrangement.
Local control switch / push buttons.
The actuator shall be suitable for operation in the climate conditions and power supply
conditions given in the specification. The actuator shall be capable of producing not lessthan 1½ time the
maximum required torque and shall be suitable for at least 15 minutescontinuous operation.
Valve operational requirements:
The operation of valves must be sequential w.r.t the pump operation. As the pump starts,
the valve shall start to open and reach 70% opening (identified by a limit switch) only
after the complete pressure / full pump speed is reached, does the valve open 100%; the
operation of this valve shall be based on time sequence w.r.t start time of respective
pump.
Actuator Specifications
Sr. No. Description Specification
1 Type Three phases rotary / linear,multiturn
2 Enclosure Standard / weather proof
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3 Output speed 10-426 RPM
4 Output torque max. 30 MKG
5 Locking system Self locking
6 Drive kW/HP 0.75/1 to 2.2/3
7 Drive Speed 1500/3000
8 Output shaft designs As per DIN 3210
9 Mechanical stopper Adjustable for gear box only
10 Coupling to suit Butterfly valves, gate valve
11 Gear reduction ratio 100:1 (max)
12 Type of gear box Spur gear/worm gear
13 Supply Conditions
a. Rated voltage 415 VAC ± 10%
b. Rated frequency 50 Hz ± 5%
c. Combined variation ± 10%
d. NO. of Phases 3 Phase (4 wire)
14 Reference Standards I. S. 325, IEC34, VDE 0530,BS 2613
15 Type of motor TEFC (Totally Enclosed Fan Cooled, Squirrel cage, induction.) / TESC (Totally
Enclosed Surface Cooled) for IP 68/ TENV (Totally enclosed naturally)
16 Drive Frame Size 80/90
17 Rotor Class KL 60
18 Protection IP 68 as per IS 13947 Part I 1993
19 Class of Insulation Class 'F' with temperature rise restricted to class 'B'
20 Duty cycle As per IS 325 - S1 continuous (S4 – Modulating as a special case) OR (S2 - 15 /
30 min as a special case.)
21 Method of starting DOL - Direct on line with suitable actuator panel
22 Reference ambient temp 50° C
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23 Motor paint corrosion proof epoxy resin paint
24 Motor duty S1 Duty motor suitable for
3 Nos. of consecutive starts in hot condition
8 Nos. of starts distributed over 15 minutes
25 Travel Switches 1 NO + 1 NC
26 Micro Switch
a. Torque Switches 1 NO + 1NC
b. Travel / Torque Switches 2 NO + 2 NC
Actuator Panels wall mounting type
non compartmentalized
dust and vermin proof, IP 66 protection
1.5mm CRCA sheet, powder coated with Siemens grey shade, 2mm CRCA sheet door
Mounting plate 2.5mm CRCA sheet
415 V , 50 Hz
single door, bottom gland plate, earthing terminal
Isolation Transformer
Primary: 0-380V-440V-470V
Secondary: 0-230V
Capacity: 300 VA
Insulation: 2.5 Kv
Rated Temperature: 55 deg. C
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Frequency: 50 Hz, with required DIN rail mounted glass fuse type 4 sq. mm screw terminals and
with extended bottom mounting angle; in output side to provide wago make push in type terminals 4 sq
mm rating.
19. Electrical Overhead Traveling (EOT) crane

In Facilities where it is applicable, the capacities of various EOT’s shall be decided as per
recommendations of IS: 875. Lifting tackle above 1 ton(and lesser than one ton also if application
requires for electric operation) capacity will be Electrically operated.
The crane shall be of single / double girder type designed from lowest sump level and up to under size of
the bridge.
Proper selection of reduction gears shall be done to run drive motors. Wherever required the motor
enclosure shall afford protection to IP: 55 of IS: 4691 and have cooling facility to IC: 41 of IS: 6362. Each
drive motor shall be fitted with an automatic electro-magnetic brake to stop the crane on interruption of the
power supply, whether intentional or accidental power failure.
Suitable end stoppers/buffers shall be provided on the bridge girder and at each end of crane rails.
The crane and hoist shall conform to IS: 3177, IS: 3832 and IS: 3938, class 2, medium duty and meet
specified operational requirements.
EOT Operations and faults shall be interfaced with respective LCP about their operations.
Lifting speed Low 0.9 meter/minute
High 3 meter/minute
L.T. speed 10 – 15 meter/minute
C.T. speed 10 meter/minute (Max.)
However illumination lights to be operated by separate switch which will not be mounted on pendant.
Other common specification:
Brakes All brakes are electro-hydraulic thrusters/ECM brake
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Operation Through pendent push button
Gear box Precise machine cut hardened material gear noiseless operation long life
Cable All cables are insulated ISI Marked
Power supply All 415:440 4 phase 50 Hz. AC supply
Control voltage 220/230 volts-50 Hz
The hoist shall comply Class II with the performance requirement IS 3177/80, IS: 3938/IS: 3832 Class 2.
The electric hoist shall be fitted with right and left handed spiral grooved cast iron drum with a rope hoist
arrangement with spring loaded rope band and guards to ensure accurate rope guidance and location.
Hoist rope shall be extra flexible, improved plog plough steel rope with well lubricated hemp core and
having 6 strands 37 wires per strand with an ultimate tensile strength of 160/180 kg/sq.mm. The braking
load for the hoist rope shall be as per IS: 2266.
Electromagnetic brake shall be provided to hold suspended load instantly, securely and automatically in
the event of the electric current being cut off whether intentionally, accidentally or due to power
failure.
The lifting hooks shall be single ‘C’ type complying with the requirement of IS: 15560 made from grade
C30/C20 carbon steel. The hook shall have a safety latch to prevent rope coming off the hook.
20. Manually Operated Overhead Crane/Hoist

Cranes shall be designed in accordance with IS 3177:1999 or BS 2573-1:1983 and runway beams shall
comply with the requirements of the design of steel structures as set out in the Civil General Specification.
Manual hoists shall be complete with hand-chain, trolley, pulley block, hook, hand and load chains, brake
and other accessories. Each hoist shall be operated on a monorail (I-beam). The factor of safety shall not
be less than 5. The load chain shall be heat-treated to give ductility, toughness and shall conform to IS
3109:1982 (Part 1). The load wheel shall be made from heavy duty malleable castings.
The hand chain shall conform with IS 8324:1988 and be made from pressed sheet steel with roller type
guarding.
Gears shall be cut from solid cast or forged steel blanks or shall be stress – relieved welded steel
construction.
Pinions shall be of forged carbon or heat treated alloy steel. Strength, quality of steel, heat treatment, face,
pitch of teeth and design shall conform to IS 2535:2004 Part 1 & 2.
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Spur and helical gears must comply with IS 4460:1995 Part 1 to 3 and worm gears with IS 7403:1974.
Bearings shall be ball and roller type conforming to IS 2513:1963.
Proper lubricating arrangements are to be provided for bearings and pinions. The brake for the lifting gear
shall be automatic and always in action.
The safe working load is to be marked in such way that it is clearly visible from the operating level.
21. Emergency equipment (General)
Fire extinguishers
There should be provision of dry powder type/ABC CO2 fire extinguishers (2/5/10 kg) for each pumping
station and switchyards at the following locations:
• Outdoor switchyard
• Indoor electrical room
• Pump rooms (maintenance bay)
• Control room
• GAS handling area
Besides above, ionisation smoke, optical smoke & heat detectors shall be provided in control room with
fire alarm panel having appropriate battery back-up. Fire alarm detectors shall be provided both below &
above false ceiling, if any Fire alarm system and public address system shall be provided at all the relevant
Facilities.
All the smoke and heat sensors shall be wired up to nearest Joint Breaker (JB) and interfaced to respective
PLC/DDC for alarm annunciations.
22. Ventilation & odour control
General
Due to the nature and combination of processes and activities likely to be employed at the waste water
treatment works it is important not to treat odour control and ventilation in isolation.
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• Ventilation
Effective and suitable provision must be made to ensure that every enclosed work place is ventilated by a
sufficient quantity of fresh or purified air.
Due to the variety of operational workplaces on the works, it is likely that no single solution will be possible
and the Concessionaire shall be responsible for selecting the most suitable methods.
The function of the building or enclosure shall determine the level of comfort which is required. Comfort
depends on the inter-relationship of the following factors;
• Air temperature
• Relative humidity
• Mean radiant temperature of the enclosing space
• Ventilation rates
The Concessionaire shall determine the air temperature and relative humidity for each enclosed space.
Generally, humidity will depend on the operational requirements of the equipment and activities undertaken
within the enclosed space. Where close control is required de-humidifiers may be required.
The mean radiant temperature of the enclosed space will be determined by the selection of the materials
and form of construction of the enclosure.
Ventilation rates shall be determined by the following factors;
• Occupancy levels
• Requirement to control the temperature or remove excessive heat.
• Requirement to avoid contamination with foul air migrating from other areas
• Requirement to pressurise a particular workspace (positively or negatively)
• Openings in the enclosing space and frequency of operation.
• Infiltration
Ventilation can be by natural draught or forced ventilation provided by mechanical means. Where
mechanical ventilation is employed, standby systems shall be used with audible and/or visible warnings
when abnormal conditions exist.
Prior to discharge to the atmosphere the exhaust stack shall be designed to ensure that noise shall
be below 65 dBA 1 metre from the unit.
Fans and Ductwork
General
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Fans shall be sized to provide the required air volume at the point of use. The Concessionaire shall be
responsible for determining the fan performance requirements. Prior to delivery to site, fans shall be tested
in accordance with BS 848:2007 (Part 1 & 3)
Belt driven fans shall be fitted with V-belt drives complying with BS 3790:1995. The drive shall be capable
of transmitting the rated motor output with provision for adjustment of belt tension.
Guards shall be provided all unprotected inlets and outlets to fans and fan belt drive. Guards shall be
galvanised steel wire mesh with apparatus not greater than 12 mm attached to a rigid galvanised frame. Belt
guards shall be galvanised steel sheet and designed for easy removal for belt replacement. Access holes
shall be provided to allow tachometer readings to be taken from the fan and motor shaft and for belt tension
to be checked.
Where protective coatings are specified for use with corrosive gases, the coating shall be cover all contact
surfaces of the fan, motor and shaft.
Flameproof enclosures shall comply with the requirement of BS EN 60079.
Centrifugal Fans
Small centrifugal circulating fans shall comply with the requirements of BS 5060:1987. Fans larger than
7.5 kW output shall be the backward bladed type having a total fan efficiency of not less than 78%
Fan casings shall be constructed from steel sheet with angle stiffeners to ensure freedom from drumming
and to withstand the maximum differential pressure of the system. Casings shall allow fan impellers to be
withdrawn, their outlets shall be flanged and a drain plug shall be fitted at their lowest point.
Impellers shall be fabricated in mild steel or aluminium with robust hubs and shall be capable of running at
10% above normal operating speed.
Shaft bearings of single inlet fans shall be mounted on a common pedestal. Bearings shall be the ball or
roller type, Pedestal bearings shall be insulated from the fan casing.
Axial and Propeller Fans
Axial flow fans shall be single stage or multistage with each impeller mounted on an independent motor to
suit the duty requirements.
Propellers fans may be ring mounted, diaphragm mounted or mounted in a casing.
Casings shall be rigidly constructed from mild steel stiffened and braced to obviate drumming and vibration.
Mounting feet shall be provided for bolting to the base or supports. Inlet and outlet ducts shall terminate in
flanged rings for easy removal. An inspection door shall be provided.
The length of the duct casing shall be greater than the length of fan and motor(s) to facilitate removal
from ductwork. Electrical connections to the motors shall be through an external terminal box secured to
the casing.
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Impellers shall be steel or aluminium with the hub keyed to the drive shaft and the assembly statically
balanced. Blades shall be of aerofoil section. Shafts shall be carried in ball or roller bearings. Lubrication
points shall be extended to the outside of the casing.
Ductwork
The design, manufacture and erection of ductwork shall be in accordance with following Buildings and
Engineering Services Association (formerly the Heating and Ventilation Concessionaire’s Association)
Codes of Practice:
• DW/142 Galvanised and Stainless Sheet Steel Ductwork (low pressure Class A)
• DW/154 Un-plasticised Polyvinylchloride and Polypropylene Ductwork
• DW/191 Resin-bonded Glass Fibre Ductwork.
The Concessionaire shall have base his design on theses codes as a minimum requirement.
The means air velocity in any section of ductwork shall not exceed 10m/s and maximum static pressure
(positive or negative) shall not exceed 500N/m2.
Where flexible ductwork is required the internal diameter of the flexible duct shall be equal to the external
diameter of the adjoining ducts. Flexible ducts shall consist of a liner and cover of though tear resistant
fabric. It shall be reinforced with a bonded galvanised spring steel wire helix between the liner and cover.
An outer helix of glass fibre cord shall ensure regular convolution. Non-metallic materials shall comply
with BS 476 for fire resistance.
• Odour Control
If active odour control is specified for the plant, or if otherwise determined to be required for operational
or environmental reasons, the odour control plant shall be in accordance with these requirements.
Notwithstanding the above, the plant layout and design will take into account the possibility of odour
production and shall be arranged to minimise nuisance as a consequence.
Waste water treatment works are provided by the public to be a source of odours. However odours are not
considered to be a arranged to be a nuisance.
To ensure that unpleasant odour can be controlled in the most efficient and cost effective manner, the design
and layout of the treatment works should take account of all opportunities to minimise the problem at an
early stage at the design. The methodology which should be adopted when designing the waste water
treatment works is to:-
• Consider systems which minimise the production of unpleasant odours;
• Maximising the distance between the vented source of any unpleasant odours and the site
boundary.
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• Restrict the release of unpleasant odours to the atmosphere by containment and, if specified,
appropriate treatment.
All odour measurements shall be made by using dynamic olfactometry.
The factors to be determined when designing an odour control system will include;-
• The odour threshold (dilution) at the inlet
• The flow rate
• The total mass of the contaminants
• The odour threshold (dilution) at the outlet
Several factors which can have an effect on odour production include:
• Nature of sewage
• Increased retention time of the sewage
• Increased saline content
• Increased septicity
• Increased ambient temperature
A well-designed odour control system shall be capable of accepting a large variation in the contaminant
loads and still maintain the designed odour threshold at the outlet.
Odour control systems shall be based on the following technology:-
• Chemical oxidation
• Biological oxidation
• Absorption onto solids
Odour masking, incineration, ozone and ultraviolet scrubber shall not be considered.
It should be noted that due to the possible changes in the characteristics of the sewage with time, any
system which is supplied must be flexible enough to allow expansion without a total re-designed of the
odour control system, including the collection systems.
Where combined technologies are proposed to remote the odour in two or more stages, the first stage would
be expected to remove the majority of the contaminants by oxidation methods and the second stage would
polish the remaining low level of the contaminants by absorption onto solids.
Any odour control system shall be available for use at all times and therefore should be designed in a
duty/standby mode. An allowance shall be made for 100% standby capacity in the extraction fan sets,
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recirculation pump sets and absorption onto solids chambers. In the event of duty pump or fan failures, the
standby set shall start automatically.
Each flow stream shall be fitted with variable control dampers, non-return valves and isolation valves.
Components which may be exposed to corrosive environments shall be manufactured from austenitic
stainless steel.
The inlet ducts shall be fitted with mesh screen and disposable dust filters.
To ensure sufficient mechanical strength the ductwork shall be coated with GRP (300 g/m2). The system
should be designed to avoid static electrical charges being built up.
Where polishing filters are proposed, a de-humidifier controlled by a relative humidistat shall be required
to ensure that the relative humidity of the air steam is limited to 70-80% before delivery to the polishing
filter.
The use of final effluent as a re-circulating fluid in the bio-scrubber shall not be permitted. The distribution
nozzles shall be enclosed and dispersal of aerosol into the atmosphere shall be minimized.
The system shall be fully automated and monitored by continuous gas monitoring equipment to control the
airflow and establish efficiency.
The treated air shall be exhausted through a purpose built exhaust stack. The factors to be considered when
designing an exhaust stack will include:-
• Capacity
• Material
• Noise and vibration
• Shape
• Visible impact of stack and plume
• Temperature
• Access for maintenance
• Sampling
• Lightning protection
The noise shall be 65 dBA at 1.0 metre from the unit.
Apart from nuisance at the boundary, high concentrations of gases may give rise to problems within the
workplace and may need control. The Occupational Exposure Limit (OEL) of H2S is 10ppm. This is the
level at which it is deemed not be harmful to operators exposed for 8 hours a day, 40 hours a week, over a
40 year working life..
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23. Water and wash water supplies
i) Type of Facility
The provision of wash water facilities shall be based on the size of works and of individual tasks.
ii) Potable Water System
Where potable water is abstracted from the public mains supply, this shall comply with current regulations
for use of potable water on contaminated sites and provide for a break tank incorporating an air gap to
prevent the possibility of back-contamination of the public water supply.
Where the final effluent quality is unsuitable for use in wash water systems and where operational
requirements for periodic hosing down of plant and equipment are required a potable water supply shall be
provided.
iii) Final Effluent Utilization System
Final effluent may be used as wash water on a site specific basis, including pressurised wash water system
for specific applications e.g. screen washing,land scaping,guardening provided that the process guarantees
are not compromised and that the health and safety and specification requirements can be met. Final effluent
shall be filtered prior to use. The filter shall be a self-cleaning strainer with a 500 micron mesh and capable
of handling a solids loading of 100mg/l.
iv) Skid Mounted Pump Sets
The flow into the break tank shall be controlled by a float operated isolating valve. The arrangement of the
pumps shall be such that there shall be a flooded suction at all times. The pumping station shall be fully
automated.
The pumps shall be required to pump water around the works wash water redial feed or ring main.
A pressurised system incorporating a suitable hydro-pneumatic vessel shall be provided to maintain the
rated pressure. The pressurised vessel shall be of the bladder type, with a replaceable EPDM membrane.
The pumps shall be uniformly sized and shall be configured on a duty/assist/standby basis. The pump size
and number shall ensure that pump starts are limited to 15 starts per hour under the worst case conditions.
Pump casing and impeller materials shall be suitable for use with potable water or final effluent. Motor
speed shall not exceed 3000rpm.
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Any leakage or spillage in the pumping station shall be directed to a suitable drain. There shall be no
possibility of the station flooding.
Each pump shall be equipped with gate valves on the suction and discharge sides and a non-return valve on
the pump side of the discharge valve.
v) Control
A fully automatic control system shall be provided. Pumps shall start and stop automatically in response to
demand and shall maintain the required pressure and flow at the outlet flange from the distribution manifold.
vi) Pipework
A radial feed or ring main shall be installed for use with a skid mounted pump-set. The pipework shall be
constructed from ductile iron or polyethylene and shall have sufficient spurs so that water can be delivered
at any location around the site on demand. Each spur shall have an isolating valve so that maintenance work
can be carried out on any hydrant.
The water take-off points shall generally be undergrounds fire hydrants of the integral valve and screwed
outlet type set in a pre-cast concrete chamber with cast iron cover.
The maximum distance between hydrants shall be 80m. The minimum diameter of the main shall be 75mm.
The main shall have cross-links so that sections can be isolated for maintenance without affecting the
operation in other areas of the site.
vii) Process Water
Where individual processes require process water at specific rates and pressures, the Concessionaire shall
make appropriate arrangements in his design to ensure that the water supplied is secure and neither
compromises nor is compromised by the wash water requirements stated above.
4.7 H.V. Motors
a) Motors shall be capable of starting and accelerating the load with the applicable method of starting,
without exceeding acceptable winding temperatures, when the supply voltage is 80% of the rated voltage.
b) Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the
rated voltage for 5 minutes, commencing from hot condition.
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c) The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than
starting time at minimum permissible voltage by atleast two seconds or 15% of the accelerating time
whichever is greater. The locked rotor current of motors shall not exceed 600% of full load current of
motors which is inclusive of 20% tolerance.
d) Motors when started with the drive imposing its full starting torque under the specified supply
voltage variations shall be capable of withstanding atleast two successive starts from cold condition and
one start from hot condition without injurious heating of windings. The motors shall also be suitable for
three equally spread starts per hour under the above referred supply conditions.
e) The three phases shall be segregated by metal barriers within both line and neutral terminal box.
f) The earthing pads shall be of non-corrodible metal, welded / brazed at two locations on opposite
sides. The pad size shall be 75 x 65 x 25 mm. With two holes drilled at 40 mm. centers, tapped and provided
with suitable bolts and washers for connecting the earthing strip.
g) At least six resistance type temperature detectors for the stator winding each having D.C. resistance
of 100 ohms at 0 degrees Celsius, embedded in the stator winding at locations where highest temperatures
may be expected, shall be provided. The material of the RTD’s shall be platinum.
h) Motors shall have space heaters suitable for 240 V single phase 50 Hz AC supply. These shall be
placed in easily accessible position in the lower part of motor frame. Provision shall be made to measure
temperature of bearing by inserting hand held temperature measuring device.
i) Motors shall have drain plugs so located that they will drain water, resulting from condensation or
other causes from all pockets in the motor casing.
6. Electric Actuator
(a) All local controls shall be protected by a lockable cover.
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(b) Each actuator shall be adequately sized to suit the application and be continuously rated to suit the
modulating control required. The gearbox shall be oil or grease filled, and capable of installation in any
position. All operating spindles, gears and headstocks shall be provided with adequate points for lubrication.
(c) The actuator shall be capable of producing not less than 1½ times the required valve torque and
shall be suitable for at least 15 minutes continuous operation.
(d) The actuator starters shall be integrally housed with the actuator in robustly constructed and
totally enclosed weatherproof housing. The motor starter shall be capable of starting the motor under the
most severe conditions.
(e) The starter housing shall be fitted with contacts and terminals for power supply, remote control and
remote positional indication, and shall also be fitted with internal heaters so as to provide protection against
damage due to condensation. Heaters shall be suitable for single phase operation. The heaters shall be
switched “ON” when the starters are “OFF” and shall be switched “OFF” when the starters are “ON”.
(f) Each starter shall be equipped as follows :
(i) 2 Nos. - Three phase magnetically operated line contactors with no-volt release and electrical and
mechanical interlock.
(ii) 1 No. - Three phase terminal cut-out device.
(iii) 1 No. - Control circuit transformer fully protected by fuses on primary and secondary circuit.
(iv) 1 No. - Set of “Open”, “Close” and “Stop” buttons.
(v) 1 No. - Local - Off-remote switch with padlocking facilities.
(vi) 1 No. - Set of torque and limit switches for “Open” and “Close” positions.
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(vii) Valve position indicator and handwheel for manual operation.
(ix) Reduction gear unit.
(g) Gearbox shall have a life of 1,00,000 hours, and be selected in accordance with AGMA
recommendation.
9. Sluice Gate
9.1 Design Requirements and Construction Features
(a) The construction of sluice gates shall be in accordance with the Specification and generally as per
AWWA C 501 or IS:13349.
(b) The sluice gates shall be capable of performing the duties set in this Specification without undue
wear or deterioration. They shall be constructed so that maintenance is kept to a minimum. All parts of
sluice gate, including lifting mechanism components shall be designed for the heads specified with a
minimum safety factor of five.
(c) All sluice gates shall be of the rising spindle type.
9.2 Frame
The frame shall be of ample section and cast in one piece. All surface forming joints and bearings
shall be machined. The frame shall be of the flange back type and shall be machined on the rear face to bolt
directly to the machined face of the wall thimble.
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9.3 Guide
(a) Guide shall be bolted to the frame or cast integrally with it and shall be machined on all bearing
and contact faces.
(b) The length of guide shall be such that it should support the gate upto the horizontal line of stem
nut pocket.
(c) Arrangement shall be made to prevent lateral movement of bolted on guides. They shall be capable
of taking the entire thrust produced by water pressure and wedging action. Wedges shall be attached
securely to the guides at points where, in the closed position, they will make full contact with the wedging
surfaces on the slides.
9.4 Seating Faces
(a) Seating faces shall be made of full width, solid section. They shall be secured firmly by means of
counter sunk fixings in finished grooves in the frame and slide faces in such a way as to ensure that they
will remain permanently in place, free from distortion and loosening during the life of the sluice gates.
(b) The faces shall be of ample section and finished smooth. The maximum clearance between the
seating surfaces, with the slide in the closed position shall not exceed 0.10 mm.
9.5 Wedging Devices
Sluice gates shall be equipped with adjustable side, top and bottom wedging devices as required to
provide contact between the slide and frame facing when the gate is in closed position. All faces shall be
machined accurately to give maximum contact and wedging action. Wedges shall be fully adjustable with
suitable adjusting screws and locknuts and so designed that they will remain in the fixed position after
adjustment.
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9.6 Gate Slides
(a) The slide shall be with strengthening ribs where required and a reinforced section to receive the
seating faces.
(b) The slide shall have tongues on each side extending its full length, and the tongues shall be
machined accurately on contact surfaces. Surfaces of the slide that come in contact with the seat facing and
wedges shall be machined accurately. The maximum allowable clearances between the slide and the slide
guide shall be
1.6 mm.
(c) An integrally cast stem nut pocket with reinforced ribs shall be provided above the horizontal centre
line of the slide. The stem nut pocket shall be provided with drain.
9.7 Stem Nut and Lift Nut
Gate shall be provided with a lower fixed stem nut for connecting the stem to the slide and a revolving
lift nut located in the lifting mechanism in the head stock. They shall be of ample design to endure the
thrust developed during gate operation under maximum gate operating condition loads in opening and
closing direction. The stem nut and slide shall be constructed to prevent turning of the stem nut in the
pocket in the slide. The stem be threaded and keyed or threaded and pinned to the stem.
9.8 Stem
The threads of the stem shall be machined cut or rolled and of the square or acme type. The number of
threads per inch shall be such as to work most effectively with the lift mechanism used. The top of the
stem be provided with a stop collar.
9.9 Stem Coupling
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The coupling shall be threaded and keyed or threaded and bolted, and shall be of greater strength
than the stem.
9.10 Stem Guides
Stem guides shall be cast, with bushings and mounted on cast brackets. Guides shall be adjustable
in two directions and shall be so constructed that when properly spaced they shall hold the stem in
alignment. Number of stem guides shall be such that unsupported length of stem shall not exceed one
hundred times its diameter.
9.11 Lifting Mechanism
(a) Sluice gate shall be operated through suitable lifting mechanism which shall incorporate suitable
gearing, if required.
(b) Lifting mechanism shall be suitable for operation by one man under all conditions. Lifting
mechanism shall incorporate a strong locking device suitable for use with a padlock or padlock and chain.
(c) The manual operation shall be of the handwheel or crank operated type and shall have a lift nut
threaded to fit the operating stem. Crank shall be removable. Ball or roller thrust bearings shall be provided
above and below the flange on the lift nut to take the load developed in opening and closing the gate with
a torque of 14 kg-m. on the crank. Fittings shall be provided to lubricate gears and bearing.
(d) The design of the lift mechanism of the hand operated gates shall be such that the slide can be
operated with a torque of not more than 7 kg-m. on the operator after the slide is unseated from wedges
based on the operating head. The maximum crank radius shall be 380 mm.
(e) All gears and bearings shall be enclosed in a cast iron housing with labyrinth seals. The lifting
mechanism shall be with a cast iron pedestal, machined and drilled to receive the gear housing and suitable
for bolting to the operating floor. The gates shall close with clockwise rotation of the crank. The direction
of rotation to close the gates shall be indicated on the lift mechanism.
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(f) A suitable means shall be provided for lubricating the stem threads directly adjacent to the lift
nut. An inspection cover shall be provided to access the lift nut and gearing.
(g) Stem shall be provided with a GI pipe cover shall be fixed to the head stock.
9.12 Fasteners
All anchor bolts, assembly bolts, screw, nuts, etc. shall be of ample section to safety withstand the
forces created by operation of the gate.
9.13 Wall Thimbles
(a) Wall thimbles shall be made of cast iron and shall be supplied along with the gate. The wall
thimbles shall provide a rigid mounting, designed to prevent warping of the gate frame during installation.
(b) The cross section of the thimble shall have the shape of the letter ‘F’. The front, or mounting
flange, shall be machined and shall be drilled and tapped to the same template used for its particular gate
frame. The frame shall be attached to the thimble with bolts of studs. The depth of the wall thimbles shall
not be less than 300 mm.
(c) To permit entrapped air to escape as the thimble is being encased in concrete, holes not lesser than
35 mm. diameter at more than 600 mm. span, shall be cast or drilled in each entrapment zone formed by
the reinforcing ribs or the flange and water stop.
9.14 Lifting Lugs
Lifting lugs shall be provided for all gates.
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Section - G5.1
General electrical specifications
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Section G5.1: General electrical specifications
1. Scope of works and responsibility of the concessionaire
The Concessionaire is advised to peruse the document in full and understand the scope of work as
detailed elsewhere in this document. He is / they are also advised to make himself / themselves
aware of the site requirements and conditions before submission of his / their bid. Clarification, if
any, required shall be made with the consultant before submission of bid.
However, nothing shall absolve the concessionaire to carry out and complete the entire works
including those minor / incidental works required for the completion of the work whether it is
explicitly brought out in this document or not.
The Concessionaire shall make appropriate arrangement for power supply provisions during
Construction Period. All power and lighting circuits shall be constructed with due regard for
personnel safety and shall comply with recognized codes of practice and local regulations. All
circuits shall be fitted with earth leakage systems.
This specification is a general specification and the applicability of various component

requirements shall be as per actual requirements from site to site basis
2. Interpretation
All the technical terms referred in this document shall have the interpretation as per the relevant
Indian standard code / Indian Electricity Rules / Indian Electricity Act etc., In case on any doubt in
any of the meanings / interpretations, the tenderer shall get the same clarified from the owner prior
to submission of bid.
3. Electrical ’s license
The electrical works shall be carried out by persons holding valid competency certificate issued /
recognised by the Licensing Board of the locality / State in which the works is to be done. The
entity (for executing electrical work) holding valid Licence / Authorisation from the Licensing
Board of the locality / State may be required for carrying out the installation work of such nature
and voltage grade.
4. Design philosophy
All equipment offered by the Concessionaire shall offer the following features:-
 Safety to personnel and equipment during operation and maintenance.

 Reliability of Services.
 Ease of maintenance.
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 Facility for ready addition of future loads.
 Convenience of operation.
 Maximum Inter-changeability of equipment.
 Minimum fire risk.
5. Codes and Standards
Whether explicitly mentioned in this specification document or not, all the engineering, systems,
equipment, materials and works being provided by the Concessionaire for this project shall conform
to the requirements of the respective latest editions / amendments of the Indian Standards
Specifications. In particular cases where relevant Indian Standards are not available, other
International Codes and Standards may be accepted, subject to Executing Agency’s specific
approval.
The design and the installation shall be in accordance with established and sound engineering
practices, standard specifications and must conform to the statutory regulations applicable.
The equipment and installation shall conform to (but not be limited to) the following (Latest
versions/editions).
 Indian Electricity Act, 1910

 Indian Electricity Rules, 1956
 The Factory Act, 1948
specifications shall be defined, prepared by the Concessionaire and submitted to the Project
Engineer for approval. The decision of Project Engineer in such case shall be final and binding on
the Concessionaire.
6. Electrical system
Unless and until specified, otherwise the complete electrical system shall be suitable to work
satisfactorily with the following system parameters
: 33 kV (E) 3 wire 50 Hz AC system of supply and subject to

System Voltage (High Voltage)
permissible variations as per IE Rules
System Voltage (Medium : 3.3 kV, 3 phase, AC system of supply subject to permissible
Voltage) variations as per IE rules
: 415 Volts Three phase 4 wire / 240 Volts Single phase 3 wire
System Voltage (Low Voltage) AC system of supply subject to permissible variations as per IE
rules
Frequency : 50 Hz and subject to permissible variations as per IE rules
Neutral Earthing : Solidly earthed
Fault Level : 25 kA at Main / Incomer level
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Control Voltage : 110 Volts DC
: 11 kV (E) 3 wire 50 Hz AC system of supply and subject to

System Voltage (High Voltage)
permissible variations as per IE Rules
System Voltage (Medium : 415 Volts, 3 phase, 4 Wire AC system of supply subject to
Voltage) permissible variations as per IE rules
: 240 Volts Single phase 3 wire AC system of supply subject to
System Voltage (Low Voltage)
permissible variations as per IE rules
Frequency : 50 Hz and subject to permissible variations as per IE rules
Neutral Earthing : Solidly earthed
Fault Level : 50 kA at Main / Incomer level
Control Voltage : 110 Volts DC
7. Service conditions
All equipment to be supplied against this specification shall be suitable for satisfactory continuous
operation under the following tropical conditions.
Maximum ambient temperature (deg C) : 50

Maximum temperature in shade (deg C) : 45
Average temperature in air (deg C) in shade : 35
Relative Humidity (%) : 60 to 80
Maximum altitude above mean sea level (Meters) : 1000
Operating Environment : Moderately hot and humid tropical climate
conducive to rust & fungus growth.
Permissible voltage drop during running at rated : <2.5%
equipment current
8. Drawings and data
The concessionaire shall furnish the following drawings and data as part of the work:
i. General arrangement showing plan, elevation and typical section views.

ii. Foundation plan showing location of fixing channels, floor openings etc.
iii. Schematic wiring drawings for each breaker.
iv. Technical literature on the equipment offered.
v. Make/ Model No. of various major electrical equipment
The Concessionaire shall also furnish the following drawings for each major equipment such as
HV panels, Transformers, MV panels, APFCR Panel, Street lighting Poles etc., after the award of
contract.
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(i) Overall outline dimensions and general arrangement including plan, front elevations,
clearances required in front and back etc.,.
(ii) Schematic control diagrams to cover controls, protection, interlocks, switch instruments,
space heaters, etc., for each type of module.
(iii) Itemized bill of material for each module, listing all devices mounted and cable glands,
indicating all type, rating quantity and special notes, if any.
(iv) Detailed internal wiring diagram of each type of module, including terminal block number,
ferrule numbers and the external cable connection designations.
(v) Inter panel interconnection wiring diagram including terminal numbers and ferrule
numbers.
9. The energy measurement point:
(i) The "point of supply" of the utility connections for measuring the electrical energy
consumption when the Facilities are running on utility power.
(ii) The Concessionaire shall also install meters and gauges at the DG Sets to measure the total
number of energy units (in kWh) consumed from the DG Sets in each month of the
O&M Period.
(iii) If the Concessionaire sets up a Power Plant at the Site, then the Concessionaire shall install
meters at the Power Plant to measure the total number of energy units (in kWh)
generated from the Power Plant in each month of the O&M Period.
(iv) All the energy recording meters shall be in conformance with the required class of accuracy
and type as mandated by the utility rules and regulations.
10. Specific project requirements for electrical equipment
10.1. HV switchboard
Description Unit Particulars

General
Type Metal enclosed,
compartmentalized, draw-out type
Rated voltage, no. of phases and rated kV / - / Hz 33kV, 3 Phase, 50Hz
frequency
System neutral earthing Effectively Earthed
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Rated Insulation Levels
- Rated short duration power frequency kV (rms) 70
withstand voltage
- Rated lightning impulse withstand voltage kV (peak) 170
Rated normal current of bus bars under A / - (*),Aluminium - suitable for 100%
0
design ambient temperature of 50 C and load including future loads
material of busbar
Rated short-time withstand current and time kA (rms) / 25 kA for 1 sec
sec
Constructional Requirements
Minimum thickness of sheet steel in mm Mm Frame – 3.0
Cold rolled (Frame/Enclosure/Covers) Doors/Covers – 3.0
Degree of protection of enclosure IP-52
Color finish shade
- Interior Glossy White
- Exterior Light Grey Semi Glossy
Cable connection Bottom entry and exit
Circuit Breakers
Type Vacuum/ SF6
Rated current inside the cubicle under design A (*) – (Breakers shall be rated for
ambient temperature at 50C final ratings of motors)
Rated operating sequence O–3 Min–CO-3 Min-CO
Rated short time breaking current kA (rms) 25
Rated short time making current kA (peak) 63.75
sec
Rated peak withstand current kA (peak) 63.75
Min. no. of auxiliary contacts 6 NO + 6 NC after internal use by
manufacturer
Type of operating mechanism
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- Normal Spring charging for closing and
tripping
- Emergency Manual and Spring charged for
closing and tripping
Auxiliary control voltage
- Closing coil / Tripping coil V 110V DC
- Spring charging motor V 110V DC
- Space heater and lighting V 230V AC
Earthing switch Required
Current and Voltage Transformers
Details of ratio, taps, burden, accuracy As per Single Line Diagram (*)
Protective Relays
Type Numerical (Microprocessor based)
Auxiliary supply V 110V DC
Details of protective relays As per Single Line Diagram
Switch-Disconnector
Rated current under design ambient A (*)
temperature of 50C
Rated making current kA (peak) 63.75
Rated peak withstand capacity kA (peak) 63.75
sec
Insulation levels
1. Rated lightning impulse withstand
voltage
- Across the isolating distance kV (peak) 170
Rated short duration power frequency
withstand voltage
- Across the isolating distance kV(rms) 70
Operating mechanism
- Closing and opening Spring charged
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- Control voltage V 110V DC
Earthing switch Required
HV Fuses
Type HRC
Rated current A (*)
Rated voltage kV 33
Rated breaking capacity kA (rms) 70
(*) Value to be as per the approved Design & Drawings.
Circuit Breaker
Circuit breakers shall be preferably vacuum type. Circuit breaker along with its operating
mechanism shall be mounted on a wheeled carriage moving on guides, designed to align correctly
and allow easy movement. Plugs and sockets for power circuits shall be silver faced and shall be
insulated with suitable insulating material shrouds. All corresponding components of circuit
breaker cubicles of same rating shall be interchangeable with one another.
There shall be ‘service’, ‘Test’ ‘Fully withdrawn’ positions for the breakers. In the ‘Test’ position
the circuit breaker shall be capable of being tested for operation without energizing the power
circuits, i.e. the control circuits shall remain undisturbed while the power contacts shall remain
disconnected. Separate limit switches, each having a minimum of 2 ‘NO’ + 2 ‘NC’ contacts, shall
be provided for both ‘Service’ and ‘Test’ positions of the circuit breakers for future SCADA.
Electrical tripping shall be performed by shunt trip coils. “Local / Remote” selector switch lockable
in “Local” position shall be provided on the cubicle door. `Red’ and `Green’ indicating lamps shall
be provided on cubicle door to indicate breaker close and open positions. Breaker “Service” and
“Test” positions shall be indicated by separate indicating lamps on the cubicle door, in case
mechanical indication of “Service” and “Test” positions are not available on the cubicle door.
Connection of the control / interlocking circuits between the fixed portion of the cubicle and the
breaker carriage shall be preferably by means of plug socket arrangement.
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Operating mechanism control
a) Circuit breakers shall be operated by a motor spring charging type of mechanism. The
mechanism shall be complete with motor, opening spring, closing spring and all
accessories to make the mechanism a complete operating unit
b) Operating mechanism shall normally be operated from the breaker cubicle itself.
c) The tripping spring shall be charged by the closing action, to enable quick tripping. Closing
of the circuit breaker shall automatically initiate recharging of the springs to enable the
mechanism to be ready for the next closing stroke. Charging time for the springs shall not
exceed 30 seconds. It shall be possible to manually charge the springs in an emergency.
Transfer from motor to manual charging shall automatically disconnect the charging motor.
All operating mechanisms shall be provided with "ON" - "OFF" mechanical indication.
The charging mechanism shall be provided with mechanical indicators to show "charged"
and "discharged" conditions of the spring. Failure of any spring, vibration or mechanical
shock shall not cause tripping or closing of the circuit breaker.
d) Only one closing operation of the circuit breaker shall result from each closing impulse
(manual or electrical), even if the breaker trips while the control device (manual or
electrical) is being held in the "close" position.
e) The circuit breaker mechanism shall make one complete closing operation, once the push
button (PB) or control switch has been operated and the first device in the control scheme
has responded, even though the PB or control switch is released before the closing
operation is complete, subject to the condition that there is no counter- impulse for tripping.
f) Means shall be provided to manually open and close the breakers slowly, when the
operating power is not available, for maintenance and adjustments. A local manual trip
device shall also be provided on the operating mechanism.
g) Circuit breaker control shall be on 110 V DC. Closing coils and other auxiliary devices
shall operate satisfactorily at all voltages between 85-110 % of the control voltage. Trip
coils shall operate satisfactorily between 70 -110 % the rated control voltage.
h) Provision for remote control shall be provided for e SCADA.
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Safety interlocks and features
a) Withdrawal or engagement of a circuit breaker / switch disconnector shall not be possible unless it
is in the open position.
b) Operation of a circuit breaker / switch disconnector shall not be possible unless it is in service
position, withdrawn to test position or fully drawn out. It shall not be possible to close the circuit
breaker electrically in the service position, without completing the auxiliary circuit between the
fixed and moving portions.
c) Circuit breaker / switch disconnector cubicles shall be provided with safety shutters operated
automatically by the movement of the circuit breaker / switch disconnector carriage to cover the
stationary isolated contacts when the breaker / switch disconnector is withdrawn. Padlocking
facilities shall be provided for locking the shutters positively in the closed position. It shall,
however, be possible to open the shutters intentionally against spring pressure for testing purposes.
d) The circuit breaker / switch disconnector carriage shall be earthed before the circuit breaker / switch
disconnector reaches the test position from fully withdrawn position. In case of breakers / switch
disconnector with automatic disconnecting type of auxiliary disconnects, the carriage shall be
earthed before the auxiliary disconnects are made and the carriage earthing shall break only after
the auxiliary disconnects break.
e) Caution nameplate, “Caution Live Terminals” shall be provided at all points where the terminals
are likely to remain live and isolation is possible only at remote end, i.e. incomer to the switchboard.
Suitable interlock shall be wired for the purpose.
Current and voltage transformers

Current Tranformer (CTs) and Vltage Trasnformers (VTs) shall have polarity marks indelibly
marked on each transformer and at the associated terminal block. Facility shall be provided for
short-circuiting and earthing the CT secondary at the terminal blocks.
CT shall be able to withstand the thermal and mechanical stresses resulting from the maximum
short circuit current. Core laminations shall be of high grade silicon steel.
VTs shall be of the single phase type and mounted on a draw out trolley. VTs shall be protected on
their primary and secondary sides by current limiting fuses with interrupting ratings corresponding
to breaker rating. It shall be possible to replace the secondary fuses safely when the switchboard is
energized. Alternatively, MCB having auxiliary contact shall be provided. Primary side fuses shall
be replaceable only in the de-energized position.
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Secondary winding of voltage transformer (VT) shall be rated for a three phase line to line voltage
of 110 V.
Identification labels giving type, ratio, output and serial numbers shall be provided for CTs and
VTs.
Constructional Features of Switchboard

Switchboard design shall comprise metal enclosed, fully compartmental and draw out execution
having separate sections for each circuit. Compartments with doors for access to operating
mechanism shall be so arranged as not to expose high Voltage circuits. Switchboard cubicle shall
be provided with hinged door on the front with facility for locking door handle.
a. Switchboard shall be dust and vermin-proof and shall have a degree of protection of enclosure of
IP 52.
b. All removable covers shall be gasketed all around with neoprene or superior gaskets.
c. Instruments, relays and control devices shall be flush-mounted on hinged door of the metering
compartment located in the front portion of cubicle. The metering compartment shall be properly
shielded to prevent mal-operation of electronic equipment such as numerical / static relays due to
electro-magnetic fields. Separate signal earth shall be provided for such devices, if necessary.
d. Each switchboard cubicle shall be fitted with a label on the front and rear of the cubicle. Each
switchboard shall also be fitted with label indicating the switchboard designation, rating and duty.
Each relay, instrument, switch, fuse and other devices shall be provided with separate label.
e. Sheet steel used for fabrication of switchboards, control cabinets, marshalling boxes, etc. shall be
cold rolled.
f. All panels, cabinets, kiosks and boards shall comprise rigid welded structural frames made of
structural steel sections or of pressed and formed cold rolled sheet steel (9 tank processed) of
thickness not less than 3 mm. The frames shall be enclosed by sheet steel of at least 3 mm thickness.
Stiffeners shall be provided wherever necessary.
g. All doors, removable covers, gland plates, etc. shall be of at least 2 mm thickness and shall be
gasketed all round the perimeter.
h. All doors shall be supported by strong hinges of the disappearing or internal type and braced in
such a manner as to ensure freedom from sagging, bending and general distortion of panel or hinged
parts.
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i. All floor mounted panels / boards shall be provided with a channel base frame.
j. It shall be possible to extend the switchboard on both sides.
k. The fully draw-out modules shall have all the circuit components mounted on withdrawable type
steel chassis. All power and control connections shall be of the draw out type. It shall be possible
to withdraw the chassis mounted circuit components without disconnecting any connections. All
draw-out contacts shall be of silver plated copper.
l. In case of circuit breaker compartments, suitable barriers shall be provided between breaker and all
control, protective and indication circuit equipment including instrument transformers such that no
live parts are accessible. External cable connections shall be through separate cable compartments
for power and control cables.
m. One metal sheet shall be provided between two adjacent vertical sections running to the full height
of the switchboard except for the horizontal busbar compartment. However, each shipping section
shall have metal sheets at both ends.
n. After isolation of the power and control connections of a circuit, it shall be possible to carry out
maintenance in a compartment safely, with the bus bars and adjacent circuits alive.
Earthing
a. A copper earthing bus shall be provided and extended throughout the length of the switchboard. It
shall be bolted to the framework of each unit and brazed to each breaker earthing contact bar. It
shall be located at the bottom of the board.
b. The earth bus shall have sufficient cross section to carry the momentary short circuit and short time
fault current for at least 1 second or higher as specified, without exceeding maximum allowable
temperature rise. The earth bus shall be properly supported to withstand stresses induced by the
momentary short circuit current.
c. Suitable clamp type terminals at each end of the earth bus shall be provided to suit the size of the
earthing conductors.
d. Bolted joints, slices, tap, etc. to the earth bus shall be made with at least two bolts.
e. Positive earthing of circuit breaker frame shall be maintained when it is in the connected position
and in all other positions whilst the auxiliary circuits are not totally disconnected.
f. Hinged doors shall be earthed through flexible earthing braid of adequate cross section.
g. All non-current carrying metal work of the switchboard shall be effectively bonded to the earth bus.
h. Positive connection of the frames of all the equipment mounted in the switchboard to the earth
busbar shall be maintained through insulated conductors of size equal to the earth busbar or the
load current carrying conductor, whichever is smaller.
429
i. All instrument and relay cases shall be connected to earth busbar by means of 1100V grade, green
colored, PVC insulated, stranded, tinned copper, 2.5 sq. mm conductor looped through each of the
earth terminals.
Circuit / busbar earthing facility

a. It shall be possible to connect each circuit or set of 3 phase bus bars of the switchboard to earth
through earthing switches.
b. Earthing switches / earthing devices shall be mechanically interlocked with the associated breakers
/ switch disconnector to prevent accidental earthing of live circuit or bus bars.
c. In case the earthing facility comprises earthing trucks to be inserted in place of circuit breakers,
separate earthing trucks shall be supplied for each type / size of breaker.
d. Auxiliary contacts (min. 2 NO + 2 NC) shall be provided on each earth switch / earthing device
and shall be wired to the terminal block for interlocking purpose.
10.2. 11 KV Ring Main Unit (RMU)
 Scope
This specification describes the minimum requirement for design, manufacture, inspection and
testing before despatch, packing and delivery F.O.R. (Destination) of SF6 insulated RMUs
complete with other accessories and auxiliaries equipments and mandatory spares, described herein
and required for their satisfactory operation.
The objective of the RMUs is for extremely small construction width, compact, maintenance free,
independent of climate, easy installation, operational reliability, safe and easy to operate, minimum
construction cost, minimum site work and minimum space requirement.
The RMUs shall conform in all respects to high standards of Engineering design, workmanship and
latest revisions of relevant standards at the time of offer.
The type of the 11 KV circuit breaker shall be VCB. Insulating medium for load break isolators,
Earth switch, 11 KV Buses and other associated equipment’s should be SF6 gas.
 General
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The insulation / dielectric media inside the stainless steel welded tank should be SF6 gas. The RMU
should be of extensible type on both sides with provision of attaching /connecting with SNAP FIT
arrangement without external bus bars additional load break switches and circuit breakers in future
whenever required.
The RMU shall be for a nominal voltage of 12 KV for 11 kV RMU using SF6 gas as insulating and
Vacuum as arc quenching medium. The RMU and combination shall be tropicalized and outdoor
metal enclosed type. The RMU metal parts shall be of high thickness, high tensile steel which must
be grit /short blasted, thermally sprayed with Zinc alloy, phosphate or should follow the 7 tank pre-
treatment process and be subsequently painted with polyurethane based powder paint. The overall
paint layer thickness shall be not less than 80 microns.
Relevant IE rules for clearances, safety and operation inside the enclosure shall be applicable. The
enclosure shall be IP54 and type tested from recognized laboratories by National Accreditation
Board of Laboratories (NABL). All live parts except for the cable connections in the cable
compartments shall be insulated with SF6 gas.
The SF6 gas tank shall be made of TIG welded stainless steel, to have the best weld quality. The
gas cubicle shall be metal enclosed with stainless steel of minimum 2 mm thickness and should be
provided with a pressure relief arrangement away from operator.
The gas tank shall be of completely welded construction. The connection of different welded
sections of gas tank by gasket and bolts, to form a RMU chamber is not acceptable.
Both the load break switches and the tee off circuit breaker shall be suitable for motorization in
future. The cable box of isolators and circuit breakers both should be of front access type. The side
and rear access cable box are not preferred as they require greater space for cable connection and
maintenance at site. Any accidental over pressure inside the sealed chamber shall be limited by the
opening of a pressure-limiting device in the rear-bottom part of the enclosure. Gas will be release
to the rear of the switchboard away from the operator and should be directed towards the bottom,
into the trench to ensure safety of the operating personnel and the pedestrians / civilians. All the
manual operations should be carried out on the front of the switchboard.
The entire units of RMU shall be enclosed in a single compact metal clad, outdoor enclosure
suitable for all weather conditions. The switchgear/steel gas tank shall be filled with SF6 as per
IEC/IS Standards relative pressure to ensure the insulation and breaking functions. The steel gas
tank must be sealed for life and shall meet the “Sealed pressure system” criteria in accordance with
the IEC 298 standard. The RMU must be a system for which no handling of gas is required
throughout the 20 years of service life.
The RMU shall have a design such that in the event of an internal arc fault, the operator shall be
safe. This should be in accordance with IEC 298 and relevant Test certificates shall be submitted
during design and detailed Engineering stage.
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 The RMU shall be tested for an minimum internal arc rating of 20 kA for 1 Sec.
Suitable temperature rise test on the RMU shall be carried out & test reports shall be submitted
during design and detailed Engineering stage. Each switchboard shall be identified by an
appropriately sized label, which clearly indicates the functional units and their electrical
characteristics devices is visible to the operator on the front of the switchboard and operations are
visible as well.
The entire system shall be totally encapsulated. There shall be no access to exposed conductors. In
accordance with the standards in effect, the switchboards shall be designed so as to prevent access
to all live parts during operation without the use of tools.
The entire 11 KV RMU are insulated by inert gas (SF6) suitable for operating voltage up to 12 KV
respectively. The 11 KV circuit breakers must be VCB breaker. It is necessary to fit an absorption
material in the tank to absorb the moisture from the SF6 gas. The SF6 insulating medium shall
be constantly monitored via a temperature compensating gas pressure indicator offering a
indication at different temperature ranges, like -25, 0, 20, 40, 60 deg centigrade, having distinctive
RED and GREEN zones for safe operation.
 Sulphur Hex fluoride Gas (SF6 GAS)
The SF6 gas shall comply with IEC 376, 376A and 376B and shall be suitable in all respects for
use in 11 KV and 22 kV RMUs under the operating conditions. The SF6 shall be tested for purity,
dew point air hydrolysable fluorides and water content as per IEC 376, 376A and 376B.
 Standards
Unless otherwise specified elsewhere in this Specification, the RMU, Switchboard (Switchgear),
Load break isolators, Instrument Transformers and other associated accessories shall conform to
the latest revisions and amendments thereof to the following standards.
o IEC 60 298/IEC 62 271-200/IS 12729:1988 - General requirement for Metal enclosed

switchgear
o IEC60129/IEC62271-102/IS 9921 - Alternating current disconnector’s (Load break
isolators) and earthing switch
o IEC 62 271-100/IEC 60 056/IS 13118:1991 - Specification for alternating current circuit
breakers.
o IEC 62 271-1/IEC 60694 - Panel design, SF6/Vacuum Circuit Breakers
o IEC 60044-1/IEC 60185/IS 2705:1992 - Current Transformer
o IEC 60265/IS 9920:1981 - High voltage switches.
o IEC 376 - Filling of SF6 gas in RMU.
o IEC 60273/IS :2099- Dimension of Indoor & Outdoor post insulators with voltage> 1000
Volts.
432
o IEC 60529/IS 13947(Part-1) - Degree of protection provided by enclosures for low voltage
switchgear and control gear.
o Indian Electricity Rules/Bills
Equipment meeting with the requirements of any other authoritative standards, which ensures equal
or better quality than the standard mentioned above shall also be acceptable. If the equipment’s,
offered by the Concessionaire conform to other standards, salient points of difference between the
standards adopted and the specific standards shall be clearly brought out in relevant schedule. In
case of any difference between provisions of these standards and provisions of this specification,
the provisions contained in this specification shall prevail. One copy of such standards with
authentic English Translations shall be furnished along with the offer.(Hard copy)
 Specific requirements in RMU
The RMUs going to be installed in the field network, will be hooked with SCADA through RTUs
and hence, RMUs used shall be compatible with SCADA RMU outdoor metal clad enclosure.
The RMU enclosure must be a metallic, it shall follows an industrialized process of manufacturing.
The RMU and combination shall be tropicalized and outdoor metal enclosed type. The RMU metal
parts shall be of high thickness, high tensile steel which must be grit/short blasted, thermally
sprayed with Zinc alloy, phosphate or should follow the 7 tank pre-treatment process and be
subsequently painted with polyurethane based powder paint. The overall paint layer thickness shall
be not less than 80 microns.
The rating of enclosure shall be suitable for operation on three phase, three wire, 11 KV, 50 cycles,
A.C. System with short-time current rating of 20 kA for 3 seconds with RMU Panels. The enclosure
should have two access doors one for the operation and relay monitoring and other for the cable
access. Both the doors should have the locking facility.
 Take OFF terminal units for future automation:
The RMU should be provided with necessary take off terminal units for future automations, located
in the front recesses / LV cubical of the RMU.
 Isolators (Load Break Type)
The load break isolators for Incoming and Outgoing supply must be provided. These should be
fully insulated by SF6 gas. The load break isolators shall consist of 630 Amp fault making/load
breaking spring assisted ring switches, each with integral fault making earth switches. The switch
shall be naturally interlocked to prevent the main and earth switch being switched ‘ON’ at the same
time. The selection of the main and earth switch is made by a lever on the facia, which is allowed
to move only if the main or earth switch is in the off position. The load break isolators should have
the facility for future remote operation. Each load break switch shall be of the triple pole, integral
earthing arrangement.
433
The isolating distance between the OFF and the ON position in the isolator should be more than 80
mm, so as to have enough isolating distance for ensuring safety during DC injection for Cable
testing.
 Earthing of Isolators and breakers (earth switch)
Necessary arrangements are provided at Load break isolators / Distribution Transformer Breaker
for selecting Earth position. Mechanical interlocking systems shall prevent the RMU function from
being operated from the ‘ON’ to ‘Earth’ on position without going through the ‘OFF’ position.
 Tee Off breaker (Vacuum)
The VCB breaker for the controlling of Transformer must be provided inside welded stainless steel
SF6 gas tank with the outdoor metal clad enclosure. The VCB circuit breaker must be a spring
assisted three positions with integral fault making earth switch. The selection of the main/earth
switch lever on the facia, which is allowed to move only if the main or earth switches is in the off
position.
The manual operation of the circuit breaker shall not have an effect on the trip spring. This should
only be discharged under a fault (electrical) trip; the following manual reset operation should
recharge the trip spring and reset the circuit breaker mechanism in the main off position.
The circuit breaker shall be fitted with a mechanical flag, which shall operate in the event of a fault
(electrical) trip occurring. The ‘tripped’ flag should be an unambiguous colour differing from any
other flag or mimic. Both the circuit breaker and ring switches are operated by the same
unidirectional handle.
The protection on the circuit breaker shall comprise of the following components:-
 3 class X protection CT’s,

 a low burden trip coil and
 a self-powered (No external DC or AC source required) IDMT protection relays
(Numeric/Microprocessor based) 3 x over current and earth fault element shall be Definite
Time type relay. The protection system should be suitable for protecting transformers of rated
power from 250 KVA onwards. The relay should be housed within a pilot cable box
accessible.
 Bushings
The units are fitted with the standardized bushings that comply with IEC standards. All the bushings
are the same height from the ground and are protected by a cable cover.
 Cable boxes
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All the cable boxes shall be air insulated suitable for dry type cable terminations and should have
front access only. Side and rear cable entry / access should be avoided, so not to have extra space
at site for cable connection and cable testing. The cable boxes at each of the two ring switches
should be suitable for accepting HV cables of sizes 3C x 240 sq.mm and circuit breaker cable
suitable up to 3C x 300 sq.mm.
The cable boxes for an isolator in it’s standard design should have sufficient space for connecting
two cables per phase.
 Cable testing facility
It shall be possible to test the cable after opening the cable boxes. The cable boxes should open
only after operation of the earth switch. Thus ensuring the earthing of the cables prior to performing
the cable testing with DC injection.
 Voltage indicator lamps and phase comparators
The RMU shall be equipped with a voltage indication to indicate whether or not there is voltage on
the cable. There should be a facility to check the synchronization of phases with the use of external
device. It shall be possible for the each of the function of the RMU to be equipped with a permanent
voltage indication as per IEC 601958 to indicate whether or not there is voltage on the cables.
 Extensible
Each RMU shall have the provision for extension by load break isolators / breakers in future, with
suitable accessories and necessary Bus Bar. The equipment shall be well designed to avoid any
kind of extension / trunking chamber for connecting and housing extensible Busbars. Extensible
isolators and circuit breakers shall be individually housed in separate SF6 gas enclosures. Multiple
devices inside single gas tank / enclosure will not be acceptable. In case of extensible circuit
breakers, the Breaker should be capable of necessary short circuit operations as per IEC at 20 KA,
and the Breaker should have a rated current carrying capacity of 200 A.
 Wiring & Terminals
The wiring should be of high standard and should be able to withstand the tropical weather
conditions. All the wiring and terminals (including take off terminals for future automation, DC,
Control wiring), Spare terminals shall be provided by the Concessionaire. The wiring cable must
be standard single-core non-sheathed, Core marking (ferrules), stripped with non-notching tools
and fitted with end sleeves, marked in accordance with the circuit diagram with printed adhesive
marking strips. The wiring should be of high standard and should be able to withstand the tropical
weather conditions. All wiring shall be provided with single core multi strand copper conductor
wires with PVC insulation.
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The wiring shall be carried out using multi-strand copper conductor super flexible PVC insulated
wires of 650/1100 V Grade for AC Power, DC Control and CT circuits. Suitable colored wires shall
be used for phase identification and interlocking type ferrules shall be provided at both ends of the
wires for wire identification. Terminal should be suitably protected to eliminate sulphating.
Connections and terminal should be able to withstand vibrations. The terminal blocks should be
stud type for controls and disconnecting link type terminals for CT leads with suitable spring
washer and lock nuts.
Flexible wires shall be used for wiring of devices on moving parts such as swinging Panels (Switch
Gear) or panel doors. Panel wiring shall be securely supported, neatly arranged readily accessible
and connected to equipment terminals, terminal blocks and wiring gutters. The cables shall be
uniformly bunched and tied by means of PVC belts and carried in a PVC carrying trough. The
position of PVC carrying trough and wires should not give any hindrance for fixing or removing
relay casing, switches etc., Wire termination shall be made with solder less crimping type of tinned
copper lugs. Core identification plastic ferrules marked to correspond with panel wiring diagram
shall be fitted with both ends of each wire.
Ferrules shall fit tightly on the wire when disconnected. The wire number shown on the wiring
shall be in accordance with the IS. 375. All wires directly connected to trip circuits of breaker or
devices shall be distinguished by addition of a red color unlettered ferrule. Inter-connections to
adjacent Panels (Switch Gear) shall be brought out to a separate set of Terminal blocks located near
the slots or holes to be provided at the top portion of the panel. Arrangements shall be made for
easy connections to adjacent Panels (Switch Gear) at site and wires for this purpose shall be
provided and bunched inside the panel. The bus wire shall run at the top of the panel. Terminal
block with isolating links should be provided for bus wire. At least 10% of total terminals shall be
provided as spare for further connections. Wiring shall be done for all the contacts available in the
relay and other equipment and brought out to the terminal blocks for spare contacts. Color code for
wiring is preferable in the following colours.
(a) Voltage supply Red, Yellow, Blue for phase and Black for Neutral
(b) CT circuits similar to the above
(c) DC circuits Grey for both positive and negative
(d) 250 V AC circuits Black for both phase and neutral
(e) Earthing Green
The wiring shall be in accordance to the wiring diagram for proper functioning of the connected
equipment. Terminal blocks shall not be less than 650 V grade and shall be piece-molded type with
insulation barriers. The terminal shall hold the wires in the tight position by bolts and nuts with
lock washers. The terminal blocks shall be arranged in vertical formation at an inclined angle with
sufficient space between terminal blocks for easy wiring. The terminals are to be marked with the
terminal number in accordance with the circuit diagram and terminal diagram. The terminals should
not have any function designation and are of the tension spring and plug-in type.
 Earthing
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The RMU outdoor metal clad, Switch Gear, Load break isolators, Vacuum circuit breakers shall be
equipped with an earth bus securely fixed along the base of the RMU. The size of the earth bus
shall be made as per IEC/IS standards Necessary terminal clamps and connectors shall be included
in the scope of supply.
All metal parts of the switchgear which do not belong to main circuit and which can collect electric
charges causing dangerous effect shall be connected to the earthing conductor made of copper
having CS area of minimum 75 sq.mm. Each end of conductor shall be terminated by
M12/equivalent quality and type of terminal for connection to earth system installation. Earth
conductor location shall not obstruct access to cable terminations.
The following items are to be connected to the main earth conductor by rigid or copper conductors
having a minimum cross section of 75 sq.mm
(a) Earthing switches

(b) Cable sheath or screen
(c) Capacitors used in voltage control devices, if any.
The metallic cases of the relays, instruments and other panel mounted Equipment shall be
connected to the earth bus by independent copper wires of size shall be made of IEC/IS standards.
The colour code of earthing wire shall be green.
Earthing wires shall be connected on the terminals with suitable clamp connectors and soldering
shall not be permitted.
 Accessories
The following spares and accessories shall be ensured along with the main equipment’s
1) Charging lever for operating load break isolators & circuit breaker of each RMU.
2) The pressure gauges indications – 1 numbers
3) Provision shall be made for padlocking the load break switches/ Circuit breaker, and the
earthing switches in either open or closed position with lock & master key.
 Testing of equipment & Accessories
Provision for testing CTs, Relays, Breakers and Cables shall be made available. The supplier shall
provide procedure and schedule for Periodical & Annual testing of equipments, relays, etc.
 Tests:
Type test
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The Concessionaire should, after award of contract during design detailed engineering,
submit copies of all Type test certificate of their make in full shape as confirming to
relevant ISI/IEC of latest issue obtained from a International/National Govt.
Lab/Recognized laboratory along with quality plan, inspection plan as per applicable Indian
standards.
 Acceptance and Routine tests
All acceptance and routine tests as stipulated in the latest IEC/ IS shall be carried out by the
supplier in the presence of owner’s representative. The supplier shall give at least 7 days
advance intimation to the owner to enable them to depute their representative for witnessing
the tests. The partial discharge shall be carried out as routine test on each completely
assembled RMU gas tank and not on a sample basis. As this test checks and guarantees for
the high insulation level and thus the complete life of switchgear.
 Additional tests
The Executing Agency reserves the right for carrying out any other tests of a reasonable
nature at the works of the supplier/laboratory or at any other recognized laboratory/research
institute in addition to the above mentioned type, acceptance and routine tests at the cost of
the Executing Agency to satisfy that the material complies with the intent of this
specification.
 Pre-commissioning tests
All the pre-commissioning tests will be carried out in the presence of the Project Engineer
and Executing Agency and necessary drawing manual and periodical test tools shall be
arranged to be supplied. During the above tests the Concessionaire’s representative should
be present till the RMUs are put in to service.
 Inspection:
The owner may carry out the inspection at any stage of manufacture. The supplier shall grant
free access to owner representative at a reasonable time when the work is in progress.
Inspection and acceptance of any equipment under this specification by the owner shall not
relieve the supplier of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection if the equipment is found to be
defective.
The supplier shall keep the owner in advance, about the manufacturing program so that
arrangement can be made for inspection. The owner reserves the right to insist for witnessing
the acceptance/routine testing of the bought out items. The owner has rights to inspect the
supplier’s premises for each consignment for type & routine test. No material shall be
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dispatched from its point of manufacture unless the material has been satisfactorily inspected
and tested / unless the same is waived by the owner in writing.
 Quality Assurance Plan:
The Concessionaire shall invariably furnish following information during Design and detail engineering
stage
(i) Statement giving list of important raw materials including but not limited to:
(a) Contact material

(b) Insulation
(c) Sealing material
(d) Contactor, limit switches, etc. in control cabinet.
Name of sub-suppliers for the raw materials, list of standards according to which the raw
materials are tested, list of test normally carried out on raw materials in presence of
Concessionaire’s representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of bought out accessories
(iii) List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.
(iv) Special features provided in the equipment to make it maintenance free.
(v) List of testing equipment available with the Concessionaire for final testing of RMUs and
associated combinations vis-à-vis, the type, special, acceptance and routine tests specified in
the relevant standards. These limitations shall be very clearly brought out in the relevant
schedule i.e. schedule of deviations from specified test requirements. The supplier shall,
within 15 days from the date of receipt of Purchase Order submit following information to
the owner.
(vi) List of raw materials as well bought out accessories and the names of sub-suppliers selected
from those furnished during Design and Detailed Engineering stage.
(vii) Necessary test certificates of the raw material and bought out accessories.
(viii) Quality Assurance Plan (QAP) withhold points for owner inspection. The quality assurance
plan and hold points shall be discussed between the owner and supplier before the QAP is
finalized.
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The supplier shall submit the routine test certificates of bought out items and raw material, at the
time of routine testing of the fully assembled breaker.
 Training
The supplier shall give rigorous training to the engineers & staff at the site for 2 days in attending
trouble shooting and maintenance.
SCADA Connectivity: Specific requirement for SCADA connectivity following requirement shall
be fulfilled:
1. FPI shall be provided per isolator

2. DC control supply system should be 110 V DC.
3. Battery charger to cater load of minimum 10 motorized operation cycles (CLOSE / OPEN)
in absence of battery.
4. Battery to cater load of minimum 10 motorized operation cycles (CLOSE-OPEN) in absence
of battery charger. The battery backup should be minimum of 2Hrs
5. Availability of MCB's for battery charger supply, RMU Motor supply & FRTU supply
(Minimum 2 Amp circuit for future use of FRTU).
6. Individual control circuit of isolator/CB/BC to have point of isolation/protection.
7. Individual motor circuit of isolator/CB/BC to have point of isolation/protection.
8. RMU shall have minimum protection of IP 54 with gland plate & knock outs. Provision for
control cable entry should preferably be from Right/ Left top through LV cable box & shall
be independent of HV isolator/CB/BC status. It should be vermin proof.
9. Control cable gland plate shall be independent of power cable gland plate.
10. A point of earthing for control cables shall be electrically isolated from power cable earthing.
11. Ambient temperature of 50 degree C max. Allowable temperature rise of battery & battery
charger above ambient 40 degree C.
12. Local / Remote switch shall be provided on all the isolator & breaker panels for selection of
controls
13. CT & PT terminals for all the circuit breakers only.
Following is the list of I/O requirements for RMU modules. Please note that all DI & DO should
be potential free contacts.
a) List of potential free contacts for Isolator (Terminals shall be provided):
Digital Indications
1. Isolator ON
2. Isolator OFF
3. Isolator Earth switch Status (ON/OFF)
4. FPI Operated
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5. LOCAL/REMOTE switch position
List of commands
1. Isolator Close
2. Isolator Open
3. FPI reset
b) List of potential free contacts for Circuit Breaker / Bus coupler (Terminals shall be provided):
Digital Indications
1. Circuit Breaker ON
2. Circuit Breaker OFF
3. Auto trip
4. LOCAL/REMOTE switch position
List of commands
1. CB Close
2. CB Open
Requirement for Multifunction Meters (MFMs):
1. Terminals shall be provided for CT and PT connections.

2. Space may be provided for MFM mounting inside control panel.
c) List of potential free signals for AUXILIARY:
Digital indications
1. RMU Battery charger fail

2. Battery Low indication
3. SF6 low
Documentation and drawings
All drawings shall conform to relevant International Standards Organization (ISO)

Specification.
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The Concessionaire shall submit after award of contract during design and detailed
engineering stage, dimensional general arrangement drawings of the equipment’s,
illustrative and descriptive literature in triplicate for various items in the RMUs, which are
all essentially required for future automation.
i) Schematic diagram of the RMU panel

ii) Instruction manuals
iii) Catalogues of spares recommended with drawing to indicate each items of spares
iv) List of spares and special tools recommended by the supplier.
v) Copies of Type Test Certificates as per latest IS/IEC.
vi) Drawings of equipment’s, relays, control wiring circuit, etc.
vii) Foundation drawings of RMU.
viii) Dimensional drawings of each material used for item Vii.
ix) Actual single line diagram of RMU/RMUs with or without Extra combinations shall
be made displayed on the front portion of the RMU so as to carry out the operations
easily.
The following should be supplied to along with the initial supply of the equipment’s ordered.
Two copies of printed and bound volumes of operation, maintenance and erection manuals
in English along with the copies of approved drawings and type test reports etc.
 Nameplate
Each RMU and its associated equipment’s shall be provided with a nameplate legible and indelibly
marked with at least the following information.
(a) Name of manufacturer

(b) Type, design and serial number
(c) Rated voltage and current
(d) Rated frequency
(e) Rated symmetrical breaking capacity
(f) Rated making capacity
(g) Rated short time current and its duration
(h) Purchase Order number and date
(i) Month and Year of supply
(j) Rated lighting impulse withstand voltage
(k) Feeder name (Incoming and Outgoing), DTs Structure name, 11000 Volts Dangers etc.
Note: Recognized abbreviations may be used to express the above and auxiliary supply shall be
stated either on the circuit breaker name plate or any other acceptable position.
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 Fault Passage Indicators (FPI):
These shall facilitate quick detection of faulty section of line. The fault indication may be based on
monitoring fault current flow through the device. The unit should be self-contained requiring no
auxiliary power supply. The FPI shall be integral part of RMU. The FPI shall have LCD/LED
display, automatic reset facility. The sensors to be bushing mounted. FPI shall be provided per
Isolator
 Tropicalisation
Due regard should be given to the climatic conditions under which the equipment is to work.
Ambient temperature normally varies between 20 °C and 32 °C, although direct sun temperature
may reach 50 °C. The climate is humid and rapid variations occur, relative humidity between 60%
and 90% being frequently recorded, but these values generally correspond to the lower ambient
temperatures. The equipment should also be designed to prevent ingress of vermin, accidental
contact with live parts and to minimize the ingress of dust and dirt. The use of materials, which
may be liable to attack by termites and other insects, should be avoided.
 Motorization
All the functions within the RMU i.e. Isolators / Breakers should be suitable for motor drive
mechanism and closing coil making it suitable to make it ON from remote.
Control Supply and Auxiliaries : Following Auxiliaries has to considered
(i) Shunt trip coil – 110 VDC for Isolators and Breakers
(ii) Closing Coil – 110 VDC
(iii) 6NO+6NC – Potential free auxiliary contacts for breakers / isolator
(iv) Auxiliary supply should be –110 V DC
(v) Local / Remote switch for breaker and Isolators
 Metering
Separate Metering Module consisting of bus connected PT’s and metering CT’s to be provided for
VCB function along with Provision of installing Multifunction meter to be provided. The PT’s and
CT’s provided shall made up of epoxy cast resin with an Accuracy class of 0.5. The CT ratio shall
be as per transformer Rating. The metering is required only in breaker functions.
10.2.1. Guaranteed Technical particulars for RMU
The Concessionaire shall submit the Guaranteed Technical particular for RMU during design and detailed
Engineering stage.
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parameters / values
Sl.
Description Parameter / value as offered by the
No.
Concessionaire
I Tag No. of Panel
Quantity
Location
Service
Combination type 2 LBS + 1 VCB
Functional Requirement Service entrance “metering &
control”
Make / Model
II 11 KV Bus Bar
Current carrying capacity 630 Amps.
Short time rating current for 3 20 KA
secs
Insulation of bus bar SF6
Bus bar connections Anti-oxide grease
III Parameters for VCB and load break isolators

Type Metal enclosed
No of Phases 3
No. of poles 3
Rated voltage 12 KV
Operating voltage 11 KV
Rated lightning impulse 75 KV
withstand voltage
Rated power frequency 28 KV
withstand voltage
Insulating gas SF6
Rated filling level for insulation As per IEC
Isolating distance between ON 80 mm (min).
and OFF position in isolator
Rated short time current 20 KA
Rated short time 3s
Rated peak withstand current 50 KA.
No of operations in Short circuit 15 Nos (minimum)
Operating mechanism Circuit breaker with spring
assisted anti reflex / trip free
mechanism.
Rated current (Bus) 630 A
Rated current (breaker) 200 A
Circuit Breaker interrupter VCB
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parameters / values
Sl.
Description Parameter / value as offered by the
No.
Concessionaire
Rated frequency 50 Hz
Rated operating sequence O-3 min - CO
10.3. 11 kV Metal enclosed switchgear
Applicable standards
The switchgear and its components shall conform to the latest applicable standards specified below.
Engineer for approval. The decis ion of Project Engineer in such case shall be final and binding on
the Concessionaire.
IS : 13118 Circuit Breakers

IS : 3427 Metal enclosed switchgear
IS : 2705 Current Transformers
IS : 3156 Voltage Transformers
IS : 5576, 11353 Arrangement for switchgear, bus bars, main connections and auxiliary wiring
IS : 2544 Bus bar support insulators
IS:13947 (Part I) Degree of Protection
IS:3231, 3842 Electrical relays for power system protection
IS:1248 Electrical indicating instruments
IS:9385 High voltage fuses
IS:722, 8530 AC Electricity Meters
IS : 613 Specification for copper rods and bars for electrical purposes
IS : 6005 Code of practice for phosphating iron & steel
IS : 9920 Alternating current switches for voltages above 1000 V
IS : 13703 Low voltage fuses
IS : 3452 Toggle switches
IS : 10118 Code of Practice for selection, installation and maintenance of switchgear and
control gear
IS : 6875 Control switches
 Features of construction
(a) The switchgear shall be outdoor, metal enclosed with separate compartments for
(i) Circuit breaker

(ii) Control, metering and relaying devices
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(iii) Busbars
(iv) Instrument transformers
(vi) Power cable terminations
(a) Adjacent switchgear cubicles shall be provided with side sheets on either side to ensure
complete isolation. The bottom of the switchgear shall be fully covered by sheet steel.
(b) Separate removable gland plates shall be provided for power and control cables. The gland
plate for the power cables shall be of non-magnetic material.
(c) All sheet steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt, and sward
by pickling, emulsion, cleaning etc. The sheet steel shall be phosphated and then painted
with two coats of zinc rich primer paint. After application of the primer, two coats of
finishing synthetic enamel paint over baked / stoved shall be applied.
(d) The circuit breaker shall be fully draw out type. The circuit breaker shall have distinct
service and test positions. In the test position, the circuit breakers shall be capable of being
tested for operation without energising the power circuits. Four normally open auxiliary
contacts shall be provided for each of the service and test limit position switches.
(e) The test position should preferably be obtained without the need to disconnect normal
control connections and use of extension cords for testing.
(f) The switchgear shall fully house the breaker both in the service position as well as in the
test position.
(g) The current transformers shall be mounted on the fixed portion of the switchgear and not
on the breaker truck.
(h) The cable compartment shall house all power cable connections along with associated
cable terminations. Wherever zero sequence current transformers are provided for earth
fault protection, these shall also be located inside the cable compartment.
(i) Each switchgear cubicle shall be fitted with a label in the front and rear of the cubicle. Each
switchgear shall also be fitted with label indicating the switchgear designation, rating and
duty. Each relay, instrument, switch, fuse and other devices shall be provided with separate
labels.
 Safety interlocks and features
(a) Withdrawal or engagement of circuit breakers or disconnecting switch shall not be possible
unless it is in the open position.
446
(b) Operation of circuit breaker or disconnecting switch shall not be possible unless it is fully
in service position, or in test position or in fully drawn-out.
(c) Operation of a disconnecting switch shall not be possible unless the associated circuit
breaker is open.
(d) Circuit breaker cubicles shall be provided with safety shutters operated automatically by
the movement of the circuit breaker carriage to cover the exposed live parts when the
breaker is withdrawn.
(e) Caution name plate with inscription ‘Caution- Live Terminals’ shall be provided at all
points, where the terminals are likely to remain live and isolation is possible only at remote
end, e.g. incoming terminals of main disconnecting switch.
(f) A draw-out with breaker of given rating shall be prevented from engaging with stationery
element of higher rating.
 Main Bus Bars
(a) Busbars shall be fully insulated by encapsulation in epoxy resin, with mould caps
protecting all joints.
(b) Busbars shall be supported on insulators capable of withstanding dynamic stresses due to
short circuit.
(c) Busbars shall be of electrolytic aluminium conductor of hard drawn and high conductivity.
 Circuit Breakers:
(a) Auxiliary contacts:

Auxiliary switch mounted on the fix portion of the breaker and directly operated from the
breaker operating mechanism shall be provided and shall have minimum 6 ‘NO’ and 6
‘NC’ potential free contracts for Purchaser’s use. Any auxiliary relays required for contact
multiplication for other requirements shall be provided. The contacts shall be rated for 10
amps, 240 V A.C and 1 Amp. (Inductive breaking), 110 V D.C. The above auxiliary
switches shall not operate when the breaker is withdrawn to test position and operated.
(b) Spring operated mechanism:

The operating mechanism shall be complete with motor, opening and closing springs, limit
switches for automatic charging and all necessary accessories. Facility for manual
charging of the closing spring shall be provided. The operating mechanism shall be trip-
free and non-pumping electrically. An anti-pumping relay to achieve electrical anti-
pumping feature shall be provided even if the breaker has provision for anti-pumping by
mechanical arrangement.
447
 Earthing:
(a) An earthing bus shall be provided at the bottom and extend throughout the length of the
switchgear. It shall be bolted / welded to the framework of each unit and each breaker
earthing bus.
(b) All non-current carrying metalwork of the switchgear shall be effectively bonded to the
earth bus. Hinged doors shall be earthed through flexible earthing braid.
(c) Positive earthing of the circuit breaker frame shall be maintained both in service and test
position.
 Annunciators:
(a) Facia annunciators, suitable for operation on 24 V DC shall be provided. Facia

annunciators shall be:
i. Equipped with ‘Sound Cancel’, ‘Acknowledge’ and ‘Reset’ push buttons common to
annunciators on all switchgear aligned together and a ‘Lamp Test’ push button for
each annunciator on individual panels;
ii. Provided with two lamps connected in parallel on each facia window with series
resistors;
iii. Suitable for normally open indicating contacts of either ‘hand’ or ‘self’ reset type;
iv. Suitable for annunciating subsequent faults with the specified sequence, immediately
after acknowledging the previous fault;
v. Facia window of minimum size of 35 mm. x 50 mm;
vi. Designed for an operating sequence indicated below :
Alarm condition Fault contact Audible alarm Visual alarm

Normal Open Off Off
Abnormal Closed On Flashing
Sound Cancel Closed or Open Off Flashing
Acknowledge Closed or Open Off Steady on
Back to Normal Open Off Steady on
Reset Open Off Off
Lamp Test Open Off Steady on
 Switchgear accessories and wiring
(a) Switchgear shall be supplied completely wired internally upto equipment and terminal
blocks and ready for external cable connections at the terminal blocks. Inner panel wiring
between cubicles of same switchgear shall be provided.
448
(b) All auxiliary wiring shall be carried out with 650 volts grade, single core, stranded copper
conductor with PVC insulation. The sizes of wire shall not be less than 1.5 sq.mm.
(c) Terminal blocks shall be of stud type, 650 volts, 10 amps, rated complete with insulated
barriers.
(d) All spare contacts and terminals of cubicle mounted equipment and devices shall be wired
to terminal blocks.
(e) Accuracy class for indicating instruments shall be 1.0. Instruments shall be 110 mm.
Square with 240o scale for flush mounting with only flanges projecting.
(f) Ammeters, voltmeters, shall be of moving iron type. The accuracy class shall be 1.0. The
range shall be indicated on the drawing / data sheets. Digital microprocessor based power
monitor shall be provided to monitor all electrical parameters, such as KVA, KW with
resettable maximum demand recorder and indicator, KVAR, KWH, KVARH, Power
Factor PF, Frequency, Voltage current etc. The power monitor shall operate off a PT
secondary of 110 volts, suitable for operation on 3-phase, 3-wire system and to measure
unbalanced loads.
(g) Control and instrument switches shall be rotary type provided with inscription plates
clearly marked to show operating position and suitable for semi-flush mounting with only
switch front plate and operating handle projecting out.
(h) Breaker control switches shall be pistol grip black and selector switches shall be oval or
knob and black. Breaker control switches shall be three-position spring return to neutral
type. Instrument selector switches shall be of the maintained stay-put type. Contacts of
the switches shall be spring assisted and contact faces shall be with rivets of pure silver.
The contact ratings shall be adequate to meet the requirements of circuit capacity in which
they are used.
(i) All push buttons shall have two normally open and two normally closed contacts unless
specified otherwise. The contacts shall be able to make and carry 5 A at 110V DC and
shall be capable of breaking 1 A inductive load at 110V DC. They shall be provided with
inscription plates engraved with their functions.
(j) Indicating lamps shall be panel mounting type with series resistors. The wattage of lamps
shall be 5 to 10 watts.
449
(k) Space heaters of adequate capacity shall be provided inside each panel. They shall be
suitable for 240V, 1 pH, 50 Hz supply. They shall be complete with HRC fuses, isolating
switches and thermostat to cut off heater at 45o C.
(l) Each switchgear panel shall be provided with 240 Volts, 1 phase, 50 Hz, 5 amps, 3 pin
receptacle with switch located in a convenient position.
(m) An interior illuminating lamp together with operating door switch and protective fuse shall
be provided.
(n) Provision shall be made for receiving, distribution, isolating and fusing of auxiliary D.C.
and A.C. supplies for controls, space heating, etc. The fuse ratings shall be so chosen as
to ensure selective clearance of sub circuit faults.
(o) Fuses shall be HRC cartridge type mounted on plug in type fuse base.
(p) The D.C. and A.C. auxiliary supply shall be distributed inside the switchgear with
necessary isolating arrangements at the point of entry and with sub-circuit fuses as
required.
 Relays
Protection relays shall be numerical (microprocessor based) type. Relays shall have
interfacing facilities to communicate data to SCADA system.
All relays shall be enclosed in rectangular shaped, dustproof cases and shall be suitable for
flush mounting.
All relays shall be accessible from the front for setting and resetting. Access to setting
devices shall be possible only after the front covers of the relays are removed.
All protective relays shall be of the draw-out type and shall be provided with operation
indicators visible from the front.
Over current / earth fault protection
a) This relay shall be of the multi-characteristics type which has a flexible mode selection
facility so that it is possible to select one mode for the over current elements and another
for the earth fault element.
450
b) Phase current range shall cover at least 50-300% of ‘In’ in steps of not more than 10%
while the earth current range shall cover at least 5-100% of ‘In’ in steps of not more than
5%.
c) The time setting range of the definite time mode shall not be less than 5 seconds in steps of
0.1 second each.
d) The time multiplier setting for the inverse time-current characteristic modes shall have a
range not less than 0.05- 1.6 in steps of 0.05.
e) Over current and earth fault relays shall have separate timers and operation indicators.
f) The high set element shall have a range of 2 - 15 times the nominal current in steps of ‘In’
and shall be of low transient overreach, with a tripping time of less than 25 ms and possible
to be selected on "blocked" position. Reset time shall be not more than 50 ms for both
elements.
g) The relays that are installed on the transformer neutral side shall be of single phase version,
but they shall have the same characteristics as the phase side relays.
Restricted earth fault protection
a) The restricted earth fault relay shall be operated from a completely separate core of line
and neutral current transformers. The dedicated CTs shall have the same magnetization
characteristics with a knee ‘emf’ value higher than the highest possible setting of the relay.
Intermediate CTs for ratio correction are not acceptable. CT sizing shall be matched with
the requirements of the relay.
b) For this protection, 1-phase high impedance relay shall be provided and all the aspects
regarding stability of the protection, dimensioning of current transformer, considering the
peak short circuit current, etc. and all the auxiliary equipment such as non-linear VDR
resistor for voltage limiting, filter for harmonics and DC component suppression and
variable shunt resistor for sensitivity adjustment, if required, shall be provided. The total
fault clearing time shall not exceed 20 m sec. at 3 x In.
c) The stability of this protection against out-zone faults shall be confirmed. A calculation to
show the proper selection of the relay up to the maximum short circuit of the switchboard
shall be submitted.
451
Under voltage relays
a) Suitable voltage operated relays for sensing loss of voltage shall be provided. The relay
shall have a drop off to pick up ratio of the order 90%. The relays shall be fast operating
type and shall be fitted with operation indication. The indication shall come on drop off or
loss of voltage.
b) Additional potential free contacts for all the relay outputs i.e. trip as well as alarm signals
shall be provided for connection to future SCADA.
Motor protection relay
a) It shall be designed to protect the motor against thermal overload, locked rotor, over current
and earth fault protection, under voltage, over voltage, phase reversal and negative
sequence.
b) Thermal setting range shall cover at least 50% to 200% of ‘In’ in steps of not more than 5
% of ‘In’.
c) Phase current range shall cover at least 5-200% of ‘In’ in steps of not more than 1% while
the earth current range shall cover at least 1-100% of ‘In’ in steps of not more than 5%.
Auxiliary relays and timers
a) Following auxiliary relays shall be provided on each breaker cubicle:
i. Trip circuit supervision relay
ii. Anti- pumping relay
b) Hand reset type lockout (tripping) relays and timers shall be provided as required in
addition to the protection relays given in the single line diagram.
c) Auxiliary relays and timers shall be rated to operate satisfactorily between 70 % and 110
% of the rated voltage.
d) Voltage operated relays with sufficient contacts to initiate tripping, alarm, annunciation for
various trip functions like Buchholz relay operation. Each relay shall have four (4) pairs of
self-reset contacts except for Buchholz and "PRD" trip which shall have hand-reset contact.
The relays shall have hand-reset operation indicators.
e) Voltage operated relays with sufficient contacts to initiate alarm and data logging for
various alarm functions for transformers, etc. shall be provided. Each relay shall have four
(4) normally open self reset contacts. The auxiliary relay for Buchholz alarm shall be
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slugged to have delay on drop off at 100 ms. The relays shall have hand reset operation
indicator.
 Instrument transformers
(a) The CTS shall withstand momentary and short time current ratings of the associated
switchgear. CTS and PTS shall be of the cast resin type and completely encapsulated.
(b) The core balance CTS shall be suitable for the respective outgoing feeders and shall be
suitably supported.
(c) PTS shall be single phase, draw out type. PTS shall be provided with fuses on both primary
and secondary sides, except those terminals that are required to be connected to earth.
These shall have an isolating link. Fuses on primary side shall have rupturing capacity
equal to the switchgear rating.
 Cable termination
(a) Necessary number of cable glands shall be supplied for terminating auxiliary power and
control cables. Glands shall be of heavy-duty brass castings, machine finished and
complete with check nut, washers, neoprene compression ring.
(b) Cable lugs for all power and control cable connections shall be supplied. The lugs shall be
tinned copper / aluminium depending on cable conductor and of solder less crimping type.
(c) All necessary materials required for terminating the power cables such as tapes, filters,
binding wires, armour clamps, brass glands etc., shall be supplied.
 Drawings and data
a) The Concessionaire shall furnish the following drawings & data during design and
detailed engineering stage:
 General arrangement showing plan, elevation and typical section views.
 Foundation plan showing location of fixing channels, floor openings etc.
 Schematic wiring drawings for each breaker.
 Technical literature on the beakers offered.
 Bill of material listing equipment designation, make type, rating etc., of various
equipment mounted on switchgear panel.
b) The Concessionaire shall furnish the following drawings for each panel & switchgear
after the award of contract.
453
 Overall outline dimensions & general arrangement including plan, front elevations,
clearances required in front and back, details of bus duct connections, if any.
 Overall outline dimensions & general arrangement including plan, front elevations,
clearances required in front and back, details of bus duct connections, if any.
 Schematic control diagrams to cover controls, protection, interlocks, instruments,
space heaters, etc., for each type of module.
 Itemized bill of material for each module, listing all devices mounted and cable glands,
indicating all type, rating quantity and special notes, if any.
 Detailed internal wiring diagram of each type of module, including terminal block
number, ferrule numbers and the external cable connection designations.
 Inter panel interconnection wiring diagram including terminal numbers and ferrule
numbers.
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10.3.1. Guaranteed Technical particulars for 33kV/11 kV panel
HV indoor VCB switchboard shall comply with the following Standards, including those referred to
therein: IEC 61869, 60265, 60282, 62271, 60529, 60694, 60787, 62271 IEC/TR2 61211 and IS 9046,
9920, 9921, 13118, 3427, 4237, 2156, 2705, 3156, 10118, 722, 13118.
Sl. No. Description Parameter / value
I Tag No. of Panel
Quantity
Location STP/SPS substation
Service Outdoor/Indoor
Functional Requirement Transformer primary control and
protection
Type ICOG, Compartmentalised, Draw Out
type
Enclosure CRCA (9 tank processed)
System Neutral Earthing Effectively Earthed
II 33kV/11 KV Bus Bar

Current Carrying Capacity (*)
Short time rating current 20 KA/40 kA
for 1 secs
Insulation of bus bar Air
III Parameters for VCB

Type Metal enclosed
No of Phases 3
No. of poles 3
Rated voltage 36 kV/12 KV
Operating voltage 33 kV/11 KV
Rated lightning impulse 170 kV/75 KV
withstand voltage
Rated power frequency 70 kV/28 KV
withstand voltage
Insulating gas Air
Rated filling level for As per governing IS
insulation
Isolating distance between 80 mm (min).
ON and OFF position in
isolator
Rated short time current 20 KA
Rated short time 3s
Rated peak withstand 50 KA.
current
455
Sl. No. Description Parameter / value
No of operations in Short 15 Nos (minimum)
circuit
Operating mechanism Circuit breaker with spring assisted anti
reflex / trip free mechanism.
Rated current (Bus) (*)
Rated current (breaker) 200 A
Circuit Breaker interrupter VCB
Rated frequency 50 Hz
Rated operating sequence O-3min- CO
IV Protection Relays Numerical (Microprocessor based)
(*)Values to be ascertained as per detail design-engineering.
10.4. 33 kV/11 kV XLPE Power cables
10.4.1. Scope
The specification covers design, manufacture, shop testing, packing and delivery of 33kV/11 kV
single/multi core, cross-linked polyethylene insulated power cables suitable for effectively
earthed neutral system.
10.4.2. Standards
Unless otherwise specified elsewhere in this specification, the rating as well as performance and
testing of the HT XLPE power cables shall conform to the latest revisions available at the time
of placement of order of all the relevant standards as listed in, but not limited to table below
IS: 8130 – 1984 Conductors for insulated electric cables and flexible cords.
IS :7098 (Part 2) – XLPE PVC sheathed cable for working voltages from 3.3 kV up to and
1985 including 33 kV.
IS: 5831 – 1984 PVC insulation and sheath of electric cables.
IS: 3975 – 1988 Mild steel wires , formed wires and Tapes for armouring of cables
IS :10462 ( Part I) – Fictitious calculation method for determination of
1983 dimensions of protective coverings of cables.
10.4.3. General constructional requirements
The HT single/multi core power cables shall normally be with stranded compacted H2/H4 grade
aluminium conductor as per IS: 8130 - 1984, provided with conductor screening (of extruded
semi-conducting cross link material) and shall be insulated with XLPE of natural colour.
Identification of cores shall be by colour, as per provision of clause 13.1 of IS: 7098 (Part 2) -
1985. The insulation (XLPE) screening shall be provided consisting of extruded semi-conducting
cross link material in combination with a metallic layer of copper tapes. Three such screened
456
cores shall be laid up together with fillers and/or binder tapes where necessary and provided with
extruded inner sheathing of heat resistant PVC conforming to type ST-2 of IS: 5831- 1984.
Maximum continuous operating temperature shall be 90 deg C under normal operation and 250
deg C under short circuit condition Armouring shall be provided consisting of single galvanized
round steel wires (In case of Single core cable armouring shall be of Non-magnetic material)
conforming to IS:3975 - 1988 (amended upto date) and over the armouring a tough outer sheath
of PVC compound shall be extruded. The PVC compound for the outer sheath shall conform to
type ST-2 of IS: 5831 - 1984 (amended upto date). The colour of the outer sheath shall be black.
The cable shall be manufactured strictly conforming to IS:7098 (Part 2) – 1985 amended upto
date and shall bear ISI mark.
10.4.4. Sequential marking of length of cable
Non-erasable Sequential Marking of length shall be provided by embossing on outer sheath of

the cable for each meter length. The quality of insulation should be good and insulation should
not be deteriorated when exposed to the climatic conditions.
10.4.5. Discharge free construction:
Inner conductor shielding, XLPE insulation and outer core shielding shall be extruded in one
operation by special process (viz. Triple Extrusion Process) to ensure that the insulation is free
from contamination and voids and perfect bonding of inner and outer shielding with insulation is
achieved.
10.4.6. Routine tests
All the Routine tests as per IS: 7098 (Part 2) - 1985 amended upto date shall be carried out on
each delivery length of cable. The result should be given in test report. Partial discharge test must
be carried out in a fully screened test cell. It is, therefore, essential that the manufacturer should
have the appropriate type of facility to conduct this test, which is routine test.
10.4.7. Acceptance tests
All Acceptance tests as per IS: 7098 (Part 2) - 1985 as modified upto date including the optional
test as per clause no 18.4 and Flammability Test shall be carried out on sample taken from the
delivery lot.
10.4.8. Packing and marking:
 Identification marks on cable:
The following particulars shall be properly legible embossed on the cable sheath at the intervals
of not exceeding one meter throughout the length of the cable. The cables with poor and illegible
embossing shall be liable for rejection.
457
a) Manufactures name and/or Trade name.
b) Voltage grade.
c) Year of manufacture.
d) Successive Length.
e) Size of cable
f) ISI mark
Packing and marking shall be as per Clause No. 21 of IS: 7098 (Part 2) - 1985 amended up to
date.
10.5. Transformers
10.5.1. Applicable standards
The power and distribution transformers shall conform to the latest applicable standards specified
below. In the event of conflict between any of these Specifications and the Codes referred, such
Engineer for approval. The decision of Project Engineer and Executing Agency in such case
shall be final and binding on the Concessionaire.
IS : 2026 Power Transformer
IS : 3639 Fittings and Accessories
IS : 1180 Distribution Transformer
IS : 6600 Loading of oil immersed transformer
IS : 335 Insulating oil
IS : 2099 Bushings for > 1000 V, AC
IS : 7421 Bushings for < 1000 V, AC
IS : 13947 (Part I) Degree of Protection
IS : 1271 Electrical insulation classified by thermal stability
10.5.2. Features of construction
(a) The transformer shall be designed for adequate capacity with 100% stand by transformer.
(b) The transformer tank shall be made from high-grade plate steel, suitably reinforced by means
of stiffeners made of structural steel sections. All seams, flanges, lifting lugs, braces and
other parts attached to the tank shall be welded. The interior of the tank shall be cleaned by
shot blasting and painted with two coats of heat resistant and oil insoluble paint. Adequately
sized manholes shall be provided for easy inspection and maintenance. All joints which may
have to be opened from time to time in the course of operation shall be of a design to permit
them to be made easily oil tight in reassembly. Steel bolts and nuts exposed to atmosphere,
458
shall be galvanised. The tank cover shall be suitably sloped so that it does not retain
rainwater.
(c) Lifting lugs and eyebolts shall be so located that a safe clearance is obtained between sling
and transformer bushings, without the use of a spreader.
(d) Transformer of rating above 500 KVA shall be equipped with detachable or separately
mounted radiator banks. Transformers of rating 500 KVA and below shall be provided with
fixed type radiators.
(e) When transformers are provided with separately mounted radiators, flexible joints shall be
provided on the main oil pipes connecting the transformer tank to the radiator banks to reduce
vibration and facilitate erection and dismantling. The interconnecting pipes shall be provided
with drain plug and air release vents.
(f) The transformer tank, radiators and conservator shall be designed taking into account the loss
of thickness due to shot blasting.
(g) The transformer core shall be constructed from high grade, non-ageing, cold rolled, grain
oriented, silicon steel laminations coated with insulation varnish. The steel laminations shall
be of “core” type.
(h) Each lamination shall be coated with insulation, which is unaffected by the temperature
attained by the transformer during service.
(i) Core lamination shall be annealed and burrs removed after cutting. Cut edges shall be
insulated.
(j) The frame work and clamping arrangements of core and coil shall be securely earthed inside
the tank by copper strap connection to the tank.
(k) Windings shall be of suitably insulated copper wire or copper strip. The windings shall be
fully shrunk under vacuum before assembly.
(l) High voltage end windings shall be suitably braced to withstand short circuit stresses and
stresses set up by surges.
(m) All taps shall be provided on the HV winding.
(n) The core and coil assembly shall be dried out and impregnated under vacuum.
459
(o) Cable boxes shall have sufficient space for segregating the cable cores and to give adequate
clearance in air between bare conductors at the terminals. Cable boxes shall be complete with
necessary cable lugs and armour grips.
(p) All auxiliary wiring from current transformers, winding temperature indicators, etc., shall be
marshalled to a separate weatherproof and vermin proof marshalling box with an independent
access cover.
(q) The marshalling box shall be complete with necessary cable glands and cable lugs. The
marshalling box and components shall comply with the requirements specified for control
cabinets indicated elsewhere in this specification.
10.5.3. Performance requirements:
(a) Transformers shall operate without injurious heating at the rated KVA at any voltage within
+ 10 percent of the rated voltage of that particular tap.
(b) Transformers shall be capable of delivering the rated current at a voltage equal to 105 percent
of the rated voltage without exceeding the limiting temperature rise.
(c) Transformer for two or more limits of voltage or frequency or both shall deliver its rated
KVA under all the rated conditions of voltage or frequency or both; provided an increase in
voltage is not accompanied by a decrease in frequency.
(d) Transformers shall operate below the knee of the saturation curve at 110 percent voltage to
preclude ferro-resonance and non-linear oscillations.
(e) Transformers shall be capable of operation continuously, in accordance with the applicable
standard loading guide at their rated KVA and at any of the specified voltage ratios. Under
these conditions, no limitations by terminal bushings, on-load tap changers or other auxiliary
equipment shall apply.
(f) The neutral terminal of windings with star connection shall be designed for the highest over
current that can flow through this winding.
(g) The transformers shall be designed with particular attention to the suppression of harmonic
voltage, especially the third and fifth, so as to eliminate wave form distortion and any
possibility of high frequency disturbances reaching a magnitude as to cause interference with
communication circuits.
(h) The Executing Agency/Project Engineer’s Representative reserves the right to reject the
transformer if the same does not meet the specification requirement subject to tolerances as
460
per IS: 2062. The rejected transformers shall be replaced by transformers complying with
the requirements to this specification at the Concessionaire’s cost.
(i) If the commissioning of the project is likely to be delayed by the rejection of a transformer,
as mentioned under h) above, the Project Engineer and Executing Agency’s Representative
reserves the right to accept the rejected transformer until the replacement transformer is made
available. Transporting the rejected and replacement transformers as well as installation and
commissioning of both the transformers shall be at Concessionaire’s cost.
10.5.4. On Load Tap Changing Gear for transformer:
(a) The OLTC gear shall be designed to complete successfully tap changes for the maximum
current to which transformer can be loaded, i.e. 150% of the rated current. Devices shall be
incorporated to prevent tap change when the through current is in excess of the safe current
that the tap changer can handle. The OLTC gear shall withstand through fault currents
without injury.
(b) When a tap change has been commenced it shall be completed independently of the
operation of the control relays and switches. Necessary safeguard shall be provided to allow
for failure of auxiliary power supply or any other contingency, which may result in the tap
changer movement not being completed once it is commenced.
(c) Oil in compartments, which contain the making and breaking contacts of the OLTC shall
not mix with oil in other compartments of the OLTC or with transformer oil. Gases released
from these compartments shall be conveyed by a pipe to a separate oil conservator or to a
segregated compartment within the main transformer conservator. A Buchholz relay shall
be installed in the above pipe. The conservator shall be provided with a prismatic oil level
gauge.
(d) Oil, in compartments of OLTC which do not contain the make and break contracts, shall be
maintained under conservator head by valved pipe connections. Any gas leaving these
compartments shall pass through the Buchholz relay before entering the conservator.
(e) Oil filled compartments shall be provided with filling plug, drain valve with plug, air release
vent, oil sampling device, inspection opening with gasketed and bolted cover with lifting
handles.
(f) OLTC driving mechanism and its associated control equipment (Local) shall be mounted in
an outdoor, weatherproof cabinet with IP 55 protection, which shall include:
 Driving motor (415V, 3-phase, 50 Hz, AC squirrel cage).
461
 Motor starting contactor with thermal overload relays, isolating switch and HRC fuses.
 Control switch: Raise / off / lower (spring return to normal type).
 Remote / local selector switch (maintained contact type).
 Mechanical tap position indicator showing rated tap voltage against each position and
resettable maximum and minimum indicators.
 Limit switches to prevent motor over-travel in either direction and final mechanical
stops.
 Brake or clutch to permit only one tap change at a time on manual operation.
 Emergency manual operating device (hand crank or head wheel).
 A five-digit operation counter.
 Electricity interlocked reversing contactors (preferably also mechanically interlocked).
 240V, 50 Hz, AC space heater with switch and HRC fuses.
 Interior lighting fixture with lamp door switch and HRC fuses.
 Gasketted and hinged door with locking arrangement.
 Terminal blocks, internal wiring, earthing terminals and cable glands for power and
control cables.
 Necessary relays, contactors, current transformers etc.
(g) Control Requirements for OLTC:
The following electrical control features shall be provided:

 Positive completion of load current transfer, once a tap change has been initiated,
without stopping on any intermediate position, even in case of failure of external power
supply.
 Only one tap change from each tap change impulse even if the control switches or push
button is maintained in the operated position.
 Cut-off of electrical control when manual control is resorted to cut-off of a counter
impulse for a reverse tap change until the mechanism comes to rest and resets the
circuits for a fresh operation.
 Cut-off of electrical control when it tends to operate the tap beyond its extreme
position.
(h) Automatic Control of OLTC:
Automatic OLTC control shall include the following items:
 Voltage setting device

 Voltage sensing and voltage regulating devices
 Line drop compensator with adjustable R and X elements
 Timer 5-25 seconds for delaying the operation of the tap changer in the first step for
every tap change operation
462
 Adjustable dead band for voltage variation
(i) OLTC panel:
The OLTC remote control equipment shall be suitable for 24 V DC supply and shall be
housed in an indoor sheet steel cubicle to be located in a remote control room. The OLTC
control panel shall comprise of rigid welded structural frames made of structural steel
section or of pressed and formed cold rolled steel and frame enclosures, doors and
partitions shall be of cold rolled steel of thickness 2 mm. Stiffeners shall be provided
wherever necessary. All doors, removable covers and plate shall be gasketed all around
with neoprene gaskets. Panel shall be dust, weather and vermin proof providing degree of
protection of IP 54, colour of finish shade for interior and exterior shall be glassy white
and light grey semi glossy shade 631 of IS-5 respectively. Earthing bus shall be of 25 x 6
mm copper.
The panel shall consist of:
(i) Control Switch : Raise / Off / Lower

(spring return to normal type)
(ii) Auto / manual selector switch (maintained contact type)
(iii) Tap position indicator
(iv) Facia type alarm annunciators with “accept” and “lamp test” facilities
 Supply failure
 Drive motor auto tripped
 Tap change delayed
(v) Necessary auxiliary relays
(vi) Lamp indications for:

 Tap change in progress
 Lower limit reached
 Upper limit reached
(vii) Cable glands for power and control cables
(viii) 240 V rated panel space heater with ON-OFF switch
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(ix) Fluorescent type interior lighting fixture with lamp and door switch
(x) HRC fuses
(xi) Terminal blocks
(xii) Internal wiring
(xiii) Earthing terminal
10.5.5. Fittings and accessories:
The following fittings and accessories shall be provided with transformer:
(a) Inspection manhole in the cover
(b) Lifting lugs for both the transformer and the core
(c) Two earthing terminals on opposite ends of the transformer tank
(d) Name plate, rating plate and diagram plate
(e) Detachable radiator banks, complete with top and bottom shut-off valves, air release plug, drain
valve and lifting lugs, suitably located thermometer pockets for measuring inlet and outlet oil
temperature and one grounding terminal for connection of grounding conductor. Fins of the
radiators shall not have sharp edges but shall be rounded shape.
(f) Conservator, complete with filling plug, sump and drain valve, and a shut-off valve on the pipe
connection between transformer tank and conservator, to permit removal of the conservator.
The conservator shall be designed to maintain an oil seal through a temperature range of 100
degree C.
(g) Oil level indicator with minimum marking.
(h) Weather proof dehydrating breather with activated alumina or silicagel as the dehydrating
agent.
(i) Magnetic type oil level gauge with low oil level alarm contact, mounted on the conservators
with waterproof and dustproof terminal box.
(j) Gas detector relays with separate alarm and trip contacts complete with shut-off valves.
464
(k) Separate drain valve, oil sampling valve with plug and top filter valve shall be provided on the
tank.
(l) Explosion vent with diaphragm for relieving pressure inside the transformer. The device shall
be rain proof after operation. For transformers of 500 KVA and above an equaliser pipe
connecting the pressure relief device to the conservator shall be supplied.
(m) Separately mounted, water proof and dustproof marshalling box housing the oil temperature
indicator and winding temperature indicator with alarm and trip contacts and marshalling
facilities for electrical devices mounted on transformer.
(n) For transformers rated 500 KVA and above, adequate number of air vents for reliving trapped
air during oil filling and during maintenance.
(o) Thermometer pockets and sensing element mounted on the transformer tank cover for
measuring top oil temperature.
(p) Four jacking pads for lifting the transformer with jacks.
(q) Pulling eyes and skids for the movement of the transformers.
(r) Bi-directional wheels for movement of the transformers.
(q) Accessories for clamping the wheel mounted transformer to the foundation in order to
withstand earthquake forces with a seismic acceleration of 0.2 g.
(t) Noise level of transformers shall be less than 80 dB.
(u) Transformer shall be supplied complete with insulating oil required for first filling plus 10%
excess oil.
10.5.6. Drawings and data
The following drawings shall be submitted for the Executing Agency’s approval:
(a) General outline drawing with binding dimensions and weights shall be submitted during design
and detailed engineering stage.
(b) General outline drawings showing plan, front elevation, and side elevation, with all fittings and
accessories, locating dimensions of cable entries, earthing terminals, foundation / floor fixing
details, jacking pads and weights of the following. :
 OLTC (Local and Remote) cabinets

 Marshalling box
465
 Cable boxes
 Disconnecting chambers
(c) Cable junction box details, mounting details, make and type number, current and voltage rating,
creep age distances and principal characteristics.
(d) Rating and diagram plates
(e) OLTC cabinets: schematic circuit diagram and actual detailed wiring diagram giving terminal
numbers within 5 months of award of Contract.
(f) Marshalling box terminal connections wiring diagram.
10.5.7. Guaranteed Technical particulars for Transformer
Sl. No. Description Owner’s requirement

2 Service Outdoor
3 Rating As per requirement of
individual facility in KVA
4 Rated Voltage
a HV winding 11,000 V(all sites except
Khairati tola MPS)/33,000 V at
Khairati Tola MPS
b LV winding 6600/3300/433 V as per
application
5 Number of Phases 3 phase
6 Rated Frequency 50 Hz
7 Vector group Dyn 11
8 Type of cooling ONAN
9 Tapings : on HV side
a Range + 5%, to – 15%
b Number of steps 8 steps 9 position
c Losses at 75° C & Principal As per IS 1180
tapping
10 No load loss at rate voltage As per IS 1180
and frequency
11 Load losses at rated current As per IS 1180
12 Total loss at maximum rated As per IS 1180
power
13 Terminal Connections
a Primary line end Cable Box
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Sl. No. Description Owner’s requirement
b Secondary line end Cable Box/Bus Duct
c Secondary neutral end One bushing each inside and
outside cable box
10.6. MV Panel Board / Switch Board construction
All MV and LV panel boards / switch boards, unless and mentioned otherwise, shall meet the
following requirements.
Type : Floor mounting, free standing, single front, fully compartmentalized,

totally enclosed, dust & vermin proof, modular in construction & fully
extensible on either sides
Conforming to : IEC 60439, 60183, 60228, 60502, 60884 and IS 7098, 5831, 8130,
1554, 10810
Construction : CRCA (9 tank processed) with following thickness:
 2.00 mm thick for frames and other load bearing members
 1.6 mm thick for doors and partitions
 3.0 mm for gland plates & of non-metallic construction for
termination of single core armoured cables
Form of separation : Form 3 B
Bus bar configuration, :  TPN bus bars with 50% neutral for all applications not involving
MOC, busbar supports, harmonic loads and with 100 % neutral for loads with harmonics.
busbar insulation, busbar  Risers (vertical busbars) shall have a continuous current rating at
compartments, cable alley least 125% of combined feeder ratings of the particular vertical
and feeder compartments section.
 Completely enclosed busbar compartment running horizontally at
the top / bottom as per actual panel configuration
 Completely enclosed compartments for vertical busbars.
 Individual feeder modules in multi-tier modular formation.
 Vertical cable alleys with removable gland plates at the bottom/ top
 Busbar supports- Non-hygroscopic / SMC/ DMC supports with
anti-tracking design and strength to withstand the dynamic forces
during short circuit current of appropriate value
 Busbar insulation – 1.1 kV grade Heat shrinkable colour coded
 Busbar connections- by using cadmium plated high tensile hardware
Bus bar MOC and sizing :  MOC – High conductivity, high strength Aluminium alloy
complying to requirements of Grade E 91E of IS 5082 (or) E.C
grade copper
467
 All bus bars to be dimensioned considering the maximum
permissible rise in temperature of 50 Degrees over ambient
temperature under normal operating conditions.
Earth bus :  Continuous Aluminium strip of adequate cross section to carry the
fault current to be run inside each shipping section.
 All compartment doors to be provided with insulated earth
continuity conductors / jumper wires
Panel height, door and  Panel height shall generally not exceed 2100 mm including the
shipping sections bottom mounting channel.
 The operating handle of the switchgear at the top most tier shall be
not more than 1800 mm from FFL.
 The operating handle of the switchgear at the lower most tier shall
be not less than 300 mm from FFL
 Panel doors (Front) – Hinged
 Panel doors (rear) – Bolted
 Bus bar chamber and cable chamber doors – Bolted
 Gaskets – Continuous type of neoprene
 Locks – Each compartment shall be with interlock to ensure that the
doors do not open with switch ON. Interlock defeat also required to
be provided
 All switchgear compartments to be suitable for LOTO arrangement.
 The panel shall generally be made in sections not exceeding 2.50
mtrs long for ease of handling and movement inside panel rooms.
Degree of protection  IP 42 for indoor panels
 IP 54 for panels meant for use in dusty and humid operating
environment
 IP 65 for outdoor panels
Finish  Powder coat finished as per IS 3618.
Cable termination  From top / bottom as per data sheet.
 Shall be suitable for terminating the number of cable runs and the
type of cable as per SLD / data sheet.
Wiring  All control wiring (Other than CT circuit) to be done using 1.5
Sq.mm PVC insulated wires
 All CT wiring shall be not less than 2.5 Sq.mm PVC insulated wires
Meters  All MFMs / Ammeters / Voltmeters and other meters as called for
in the SLD shall be suitable for flush mounting type on panel
compartment doors and shall be digital versions with RS 485
communication feature.
Relays  Shall be as per SLD /data sheet
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Control Supply  Shall be derived using 415 / 110 V AC control transformer and with
MCB protection on both primary and secondary side of the control
transformer for LT panel & 110V DC for 6.6/3.3kV panel
Space Heaters  All bus bar compartments shall be provided with space heater to
prevent moisture condensation and maintain cubicle temperature 5
degree C above the ambient. The space heaters shall be located
suitably and shall be controlled through thermostats with suitable
setting with MCB.
Indication lamps  LED cluster type. The lamps shall have red, green, amber, Blue and
white caps as applicable made out of temperature resistant prismatic
glass. The lamp holders and caps shall be guaranteed for continuous
operation of lamps without any damage.
Control switches / Push  Control and instrument selector switches shall be rotary type
button actuators provided with escutcheon plates clearly marked to show operating
position and suitable for semi-flush mounting with only the switch
joint plate and operating handle projecting out. The connection
shall be from the back.
Legend plates / name  Each compartment of the PANEL / MDB / PDB / MCC/ PMCC
plates / warning boards shall be provided with a nameplate engraved with its designation.
The nameplates shall be rear engraved perspex with white letters on
black background. The name plate shall also indicate the rating of
the switchgear, the equipment fed and its rated power (in kw or hp)
 Metallic nameplate shall be provided on any one side of the panel /
switch board duly indicating as a minimum the name of the panel
vendor, the P.O No. & date, the month & year of installation,
 Warning stickers with danger signage & text in trilingual (English /
Hindi and Local language) red letters on white background shall be
provided at appropriate locations.
Mimic display  The panel front facia shall be provided with mimic key SLD (either
red painted or with red sticker)
10.6.1. Control and switchgear specifications
 All control gear and switchgear shall be ROHS compliant

 All control and switchgear, unless and mentioned otherwise, shall meet the following
requirements.
VCB/ACB : EDO type

Pole configuration : As per equipment requirement
Breaking Capacity : As per system requirements
Protection type : O/L, S/C and E/F
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Accessories : UV, Earth Fault and Shunt release (two of the accessories as per data
sheet)
Auxiliary contacts : 2 NO and 2 NC minimum
MCCB : Panel internal mounted with door mounted rotary handle operated type
Pole configuration : As per equipment requirement
Breaking Capacity : As per system requirements
Protection type : Thermal magnetic up to 63 Amps
Microprocessor based for ratings 100 Amps and above
Cable termination : All MCCBs for terminating cables above 35 Sq.mm shall be with
spreader links
Accessories : UV, Earth Fault & Shunt release (two of the accessories as per data
sheet)
Auxiliary contacts : 2 NO and 2 NC minimum
MCB : DIN rail mounted with dolly handle operated type

Pole configuration : As per requirement at individual facility
Breaking Capacity : As per requirement at individual facility
Protection : O/L & S/C
Cable termination : All MCBs for terminating cables above 16 Sq.mm shall be with spreader
links
Fault Level : 10 kA for MCBs rated more than 25 Amps
Motor Starter : Based on Type -2 co-ordination charts

component rating
Motor starter type : Upto and including 5 HP– DOL
Above 5 HP and upto and including 30 HP – Star Delta starting
Above 30 HP and upto and including 50 HP – Soft start
Above 50 HP – VFD
Additional protection : Current sensing type single phase and phase reversal protection
Metering and CT : For motors upto 10 HP CT shall be provided in the centre phase
complete with ammeter. For motors above 10 HP CT shall be provided
in all three phases complete with ammeter and ammeter selector switch
Cable termination : All terminations for cables above 16 Sq.mm shall be with spreader links
Note: Apart from the above guidelines, the concessionaire shall consider VFD for various
applications irrespective of their rating wherever the process / application warrants provision of
such variable speed requirements.
10.7. DC Equipment
DC equipment shall comply with IEC 60896 including those standards referred to therein.
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Requirements
Following items shall be covered in Concession Agreement:
a) One no 110 V Nickel Cadmium type Battery.
b) Two nos. Float-cum-boost chargers for 110 V battery
c) DC distribution board.
All connections between battery, battery chargers and DC distribution board shall be designed for
effective segregation between positive and negative leads.
110 V Battery
Battery offered shall be Nickel Cadmium (Ni-Cd) type. Nickel hydroxide and Cadmium hydroxide
shall be used for positive and negative electrode respectively. Aqueous solution of Potassium
hydroxide with small quantities of lithium hydroxide shall be used as electrolyte. It shall be used
only for ion transfer and shall not chemically changed during charging/ discharging.
The containers shall be transparent and preferably be made of toughened glass or plastic and
provided with acid level indicator.
The battery shall be rated on 5-hour basis and for the specified ambient temperature. The battery
shall have maximum recharge time of 8 hours. The batteries shall be sized for a backup of 2 hours,
in case of power failure. The ampere-hour capacity shall be selected to cater to all the emergency
loads, operation of control gear, indication lamps, annunciation panels, emergency lighting,
incoming breaker(s) spring charging currents, short time loads etc. A margin of about 25% shall be
taken to cater to the contingencies.
Terminal posts shall be designed to accommodate external bolted connection conveniently and
positively. Each terminal post shall have two bolt holes of the same diameter, preferably at right
angles to each other. The bottom hole shall be used to terminate the inter-cell connection. The top
hole shall be left for external terminal connections. Bolts, heads and nuts, except seal nuts, shall be
hexagonal and shall be lead covered. The junction between terminal posts and cover, and between
cover and container shall be so sealed as to prevent any seepage of electrolyte.
Required quantity of electrolyte for first filling with 10% extra shall be supplied in non-returnable
containers.
Each battery shall be complete with following accessories, as applicable, that include, but are not
limited to:
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a) Battery racks
b) Porcelain insulators, rubber pads, etc.
c) Set of inter-cell, inter-tier and inter-bank connectors as required for the complete
installation.
d) Electrolyte for first filling + 10% extra.
Accessories for testing and maintenance
i. One - -3, 0, +3 volts DC voltmeter with built-in discharging resistor and

suitable leads for measuring cell voltage.
ii. One - Filler hole thermometer fitted with plug and cap and having
specific gravity correction scale.
iii. Three - Pocket thermometers
iv Two - Cell lifting straps
v One set - Terminals and cable boxes with glands for connecting cable as
Each of required.
Spare connectors
Spare vent plugs
Spare nuts and bolts
Suitable set of spanners
Each battery shall be mounted in a manner that permits easy accessibility to any cell. The racks
shall be suitable for fixing on flat concrete floor. The complete racks shall be suitable for bolting
end to end.
It shall be the responsibility of the Concessionaire to provide batteries of adequate capacities to

meet specified requirements pertaining to control, indication, annunciation, etc. and emergency
lighting. For computing battery capacity, it shall be assumed that the battery is fully charged at the
beginning of loading cycle and is discharged to a voltage of 1.2 volts per cell at the end of the
loading cycle.
The battery shall have minimal difference (approx. 0.3 V per cell) between float and boost charging
voltages.
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Battery Charger (110 V)
.
The float-cum-boost type battery charger shall comprise silicon controlled rectifiers (SCRs)
connected in a full wave bridge circuit.
Each battery charger shall be suitable for float charging the battery under normal conditions and
boost charging the battery when it has discharged during service conditions. The changeover from
float to boost mode and vice versa shall be automatic.
The rectifier transformer shall be dry type and double wound with required number of taps.
The DC output voltage during float charging shall be stabilized within + 1% of the set DC bus
voltage for AC input voltage variation of +10%, frequency variation of + 5% and DC load variation
from 0 - 100%. The voltage regulation shall be achieved by a constant voltage regulator having fast
response SCR control. The ripple content shall be within 1% of DC output nominal voltage with
battery disconnected and shall be designed to have voltage regulation of 1%. Also in any mode of
operation, the maximum harmonics in the charger output shall not exceed 5%. The setting of the
output DC bus voltage shall be adjustable between + 10% of nominal rated voltage. There shall be
provision for manual control if automode fails. Line surge suppressers shall be provided.
For boost charging the discharged battery after a mains failure, the rectifier shall charge the battery
at high rate limited to the maximum boost charging voltage. The boost charging shall come on only
when selected for boost mode manually. In auto control, the DC output current shall be stabilized
within +2% for AC input voltage and frequency variation of + 10% and + 5% respectively. There
shall be provision for manual control if auto-mode fails. Boost charging time for charging the
battery to full capacity from fully discharged condition shall not exceed 8 hours.
In the float charging mode, the charger shall be designed for supplying:
a) The DC loads of control, indication and annunciation circuits that remain energized during
normal operation and the momentary closing and trip coil loads of circuit breakers, vacuum
contactors; and
b) The float charging current of the battery.
c) 25% margin over the above load
Battery charging equipment complete with all accessories shall be housed in a free standing sheet
steel cubicle having degree of protection of IP 4X. Sheet steel used for construction shall be 1.6 or
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2 mm thick. The units shall be wired using 1100 V grade, PVC insulated, stranded copper conductor
cables.
Each battery charger shall be provided with accessories that include, but not limited to the
following:
a) Silicon controlled rectifiers connected in full wave bridge circuit with ripple control
devices and transient suppression network.
b) Double wound dry type transformer with taps
c) Automatic voltage regulator unit with manual / auto control switch
d) Coarse and fine control potentiometers for manual control
e) Selector switch for mode of charging i.e. float charging / boost charging
f) Off-load tap changing switch for changing the taps of the transformer
g) DC voltmeter with fuses and a three position selector switch
h) DC ammeter with shunt
i) AC ammeter with selector switch for incoming AC power
j) AC voltmeter with selector switch for incoming AC power
k) MCB for incoming AC supply along with surge suppressers
l) Switch-fuse / MCB on DC output side with kick fuses and alarm contacts
m) Voltage dropping diodes in load circuit during boost charging mode
n) DC under voltage relay and earth fault relay
o) AC / DC switching relays for alarm and indication circuits including buzzer
p) Cubicle space heater suitable for 230 V AC, 1 ph, 50 Hz supply, with MCB and thermostat
q) 230 V AC compact fluorescent lamp fixture for internal lighting with MCB
Each battery charger shall be provided with the following alarms / indications:
a) AC and DC supply 'ON'
b) AC and DC supply fail
c) Modes of charging
d) Over voltage
e) Under voltage on DC side
f) Earth fault on DC side
g) AC / DC MCB trip
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110 V DC Distribution Board (DB)
The distribution board shall be of floor mounting design. Entry for incoming and outgoing cables
shall be from the bottom. Bus bars shall be of aluminium or copper.
Incomers, bus coupler and outgoing circuits shall be controlled by suitably rated double pole MCBs
type suitable for DC application.
Constructional features, pre-treatment, painting and other aspects shall comply with the
specifications for LV switchboard.
Aluminium earth busbar of suitable size shall be provided along the length of the DB at the bottom.
Two nos. earthing terminals shall be provided on the external face of the board for connection to
the earthing grid.
10.7. Capacitors and APFC Panel
Capacitors shall comply with IEC 60871 and IS 5553, 13925 including those standards referred to
therein. The technical parameters of capacitors shall be as given below:
LV Capacitors and Control Panel

Capacitor Bank
Application Power factor improvement
Arrangement Automatic Power Factor Correction (APFC)
Type of insulation Polypropylene (APP) / Mixed Dielectric (MD)
Rated output kVAR (*)
Rated voltage V 415
Rated frequency and no. of Hz / - 50, 3 Phase
phases
Capacitor bank connection Delta
Type of mounting and Floor mounted and Indoor
location
Design ambient temperature C 50
Type of switching Automatic
Control supply 230 VAC from UPS of PLC system
No. of steps for control Nos. Minimum 8
Degree of protection of IP52
enclosure
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Color finish shade Light Grey Semi Glossy
Type of APFC relay Microprocessor based automatic power-factor
correction relay (maximum setting 0.99 lag) with
plc interface through RS485 communication to
PLC
(*) Value to be identified as per the approved Designs and Drawings.
MV capacitors shall be provided for connection across MV motor terminals while LV capacitors
with APFC relay and a panel shall be provided for connection to LV switchboard bus, where
specified.
Design criteria
 MV capacitors – Capacitor rating shall be such that capacitor current is less than 90% of the
magnetizing current of the motor or for improvement of rated motor power factor to 0.95,
whichever is lesser.
 LV capacitors – Rated for improvement of power factor on LV side to 0.95
General
The capacitor bank shall be complete with all parts that are necessary or essential for efficient
operation. Such parts shall be deemed to be within the scope of supply whether specifically
mentioned or not. It shall be complete with the required capacitors along with the supporting post
insulators, steel rack assembly, aluminium bus bars, copper connecting strips, foundation channels,
fuses, fuse clips, etc. The steel rack assembly shall be hot dip galvanized.
The capacitor bank shall comprise of suitable number of single phase units in series parallel
combination. However, the number of parallel units in each of the series racks shall be such that
failure of one unit shall not create an over voltage on the units in parallel with it, which will result in
the failure of the parallel units. The assembly of the banks shall be such that it provides sufficient
ventilation for each unit.
Each capacitor case and the cubicle shall be earthed to a separate earth bus.
Capacitors shall be of polypropylene type. Each unit shall satisfactorily operate at 135% of rated
kVAR including factors of over voltage, harmonic currents and manufacturing tolerance. The units
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shall be capable of continuously withstanding satisfactorily any over voltage up to a maximum of 10
% above the rated voltage, excluding transients.
Each capacitor unit / bank shall be fitted with a directly connected, continuously rated, low loss
discharge device, if required, to discharge the capacitors to reduce the voltage to 50 volts within one
minute upon disconnection.
Unit protection
Each capacitor unit shall be individually protected by a HRC fuse suitably rated for load current and
interrupting capacity, so that only the faulty capacitor unit will be disconnected without causing the
bank to be disconnected. An operated fuse shall give visual indication so that it may be detected
during periodic inspection. The fuse breaking time shall co-ordinate with the pressure built up within
the unit to avoid explosion. Mounting of the individual fuse should be internal to the capacitor case.
Capacitor (APFC) control panel for LV application

APFC microprocessor-based relay shall automatically switch ON / OFF the capacitor banks to attain
the value of ‘pf’ close to the set value. Switching shall follow first in first out (FIFO) method to
ensure uniform use of all capacitor banks. At least eight steps shall be provided for switching.
Harmonic filter (inbuilt with APFC panel) shall be provided to restrict Total Harmonic Distortion
(THD) to 3% or less.
Capacitor and capacitor control shall be housed in a metal enclosed cubicle. Capacitor shall be housed
in the lower compartment and capacitor control unit at the top compartment, the two compartments
being segregated.
The cubicle shall be fabricated out of 2 mm thick cold rolled sheet steel and shall of a degree of
protection of IP 52(for Capacitor Panel IP 52is applicable as cut out for fan for heat dissipation.).
The panel shall be of indoor type and shall consist of:
a) Isolating MCCB
b) Contactors with overload element
c) Relays responsive to current / voltage / kVAR / pf for automatic switching
d) Sequencing devices, timers and auxiliary relays for automatic sequential switching of capacitor
units in and out of circuit
e) Auto-manual selector switch
f) Microprocessor based Automatic Power Factor Correction (APFC) Relay
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g) Push button for opening and closing the power circuit
h) Red and Green lamps for capacitors ON / OFF indication
i) Protective relays to protect the healthy capacitor units when one unit fails in a series connection
j) Space heater and cubicle lighting
10.8. Motors
a. All motors shall be of premium efficiency with rating of IE 3 and comply with IEC 60034-
30:2008, and IS 12615:2011, IEC 60072/ IS 325, 4691, 6362,4029,12065, 12075, including
standards referred to therein and other applicable standards:
b. The technical parameters of motors shall be as below :

Type Squirrel cage Induction motor (TEFC/TETV or
better for 3.3 & 6.6 kV/ATEX Certified explosion
proof for installation in and in the vicinity of Gas
Holders and Digesters)
Rating kW (*)
Rated voltage kV 0.415/3.3/6.6
Type of mounting Vertical / Horizontal (As required)
Duty type Continuous (S1)
Method of starting For motor rating up to 3.7 kW DOL/star-delta
starter shall be considered. Above 3.7 kW motor
soft starter shall be considered & VFD shall be
considered based on process requirement
Type of system earthing Effectively earthed
Class of insulation F
Design ambient temperature C 50
Limits of temperature rise of
winding
- Determination by resistance C 70
method
- Determination by ETD method C 80
Location Indoor
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Degree of Protection IP55
Cooling designation IC411 / IC0151/other as per requirement
External cable details As per design
Space heater for motor Required for rating 30kW and above
(*) Value to be identified in line with the approved Design and Drawings.
c. The LV motors shall be of the totally enclosed fan cooled type, with degree of protection for
enclosure of IP 55 and shall be suitable for continuous operation and direct-on-line starting,
unless otherwise specified.
d. They shall be suitable in all respects for service in extreme climatic conditions. Main conductor
and slot insulation shall be non-hygroscopic and in accordance with Class F of IEC 60085.
e. Motors shall be capable of operating continuously at rated output at any frequency between 49
and 51 Hz and at any voltage within + 10% of the nominal value (may vary for VFD operable
motors). Motors shall be designed to be operated for a period of not less than five minutes at a
voltage of 20% below the nominal value and at normal frequency without injurious
overheating.
f. The starting current at rated voltage when started direct-on-line shall not exceed 6 times the
rated full load current. When started with soft starter it should be 2.5 to 3 times the rated full
load current. The motor characteristics shall be co-ordinated with soft starter manufacturer.
g. All bearings shall be fitted with oil or grease lubricators. Vertical shaft motors shall have thrust
bearings.
h. All terminals shall be of the stud type of adequate size for the particular duty, marked in
accordance with an approved standard and enclosed in a weatherproof box.
i. All terminal boxes shall be fitted with an approved sealing chamber, conduit entry or adapter
plate, as required, together with the necessary fittings to suit the type of cable specified.
j. The power rating of the motors shall be larger of the following: 115% of the power input to the
pump at duty point at a speed corresponding to a frequency of 50 Hz.
k. Motors shall be capable of starting and accelerating the load with the applicable method of
starting, without exceeding permissible winding temperatures, when the supply voltage is 80%
of the rated voltage.
l. Motors shall be capable of satisfactory operation at a supply voltage of 80% of the rated voltage
for 5 minutes, commencing from hot condition.
m. The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than
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the starting time at minimum permissible voltage by at least two seconds or 15% of the
accelerating time, whichever is greater. The locked rotor current of motors shall not exceed
600% of full load current of motor and for IE3 motors the current shall not exceed 800%, which
is inclusive of 20% tolerance.
n. In case of motors started by soft starters, the three phases shall be segregated by metal barriers
within both line and neutral side terminal boxes. The two terminal boxes shall be on opposite
sides.
o. The earthing pad shall be of non-corrodible metal, welded / brazed at two locations on opposite
sides. The pad size shall be 75x65x25 mm with two holes drilled at 40mm centers, tapped and
provided with suitable bolts and washers for connecting the earthing strip.
p. Motors above 30 KW shall have space heaters suitable for 230 V, single phase 50 Hz AC
supply. These shall be placed in easily accessible positions in the lower part of motor frame.
Provision shall be made to measure temperature of bearing by inserting hand held temperature
measuring device.
q. Motors shall have drain plugs so located that they will drain water, resulting from condensation
or other causes from all pockets in the motor casing.
r. Pockets shall be provided in the motor bearing housings for insertion of portable instrument
probes for measuring bearing temperature. One portable hand held instrument per pumping
station shall be provided for measuring motor bearing temperature. The same instrument shall
also be used to measure the pump bearing temperature.
s. For Non-submersible motors- As per CPHEEO manual, LT (415V) motors upto maximum 250
KW and HT motors above 250 kW are to be considered. However, any of LT or HT motors
may be chosen between 225kW-250kW based on relative economics of investment and running
cost.
For Submersible motors- LT motors upto 335 kW may be considered. HV motors are not allowed. .
A) Insulation
Any joints in the motor insulation such as at coil connections or between slot and winding sections,
shall have strength equivalent to that of slot sections of the coil. The insulation shall be given
tropical and fungicidal treatment for successful operation of the motor in extreme climate. The
motors shall be provided with class F insulation with temperature rise limited to that of class B
insulation.
B)Constructional features
The motor construction shall be suitable for easy disassembly and re-assembly. The enclosure shall
be sturdy and shall permit easy removal of any part of the motor for inspection and repair.
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Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate
safe lifting.
The rotor bars shall not be insulated in the slot portion between the inner core laminations for
squirrel cage motors.
C)Terminal box
Terminal boxes shall be of weather proof construction designed for outdoor service. To eliminate
entry of dust and water, gaskets of neoprene or equivalent approved shall be provided at cover
joints and between box and motor frame. It shall be suitable for bottom entry of cables. It shall be
suitable of being turned through 360 degree in steps of 90 degree.
The terminals shall be of stud type with necessary plain washers, spring washers and check nuts.
They shall be designed for rated current carrying capacity and shall ensure ample phase to phase
and phase to earth clearances. Suitable cable glands and lugs shall be supplied to match specified
cables.
10.9Accessories
Two independent earthing points shall be provided on opposite sides of the motor for bolted
connections. These earthing points shall be in addition to earthing stud provided in the terminal
box.
10.10 Tests
Motors shall be subject to routine tests which shall also include the following:
- insulation resistance
- Measurement of winding resistance
- high voltage test
- no load / full load tests to determine efficiency, power-factor and slip
- momentary overload test
- test for noise levels of motor
- test for vibration severity of motor
- overspeed test
- locked rotor reading of voltage, current and power input at a reduced voltage.
Type test certificates for test runs performed on identical motors (below 11 kW rating) shall be made
available. Whenever two nos. or more identical motors (above 11 kW rating) are being offered, type tests on
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one of them shall be carried out, including heat run test. At the time of submission of the data sheet for
motors, based on the Jal Nigam’s concurrence, the Concessionaire can submit old type test certificates
provided that it is not older than 3 years at the time of dispatch and 5 years at COD.
10.11 Soft starters for LV motors
The soft starters shall comply with the requirements of IEC 60034, 60947 and IS 325 including
those standards referred to therein.
Constructional and performance features
Motor soft starters shall be switched or electronic type.
Soft starter panel shall be indoor, metal clad with separate metal enclosed compartments for
a) control, metering and current transformers for differential protection, if specified

b) shorting (bypass) arrangement
c) bus bars
d) power cable terminations
e) push buttons with indicating lamps.
Soft starter shall achieve smooth starting by torque control for gradual acceleration of the drive
thus preventing jerks and extending the life of equipment.
Starting current shall be limited to 2.5 to 3 times the rated current of the motor. The soft starter
manufacturer shall co-ordinate with motor manufacturer for this purpose.
Separate removable gland plates shall be provided for power and control cables.
Each cubicle shall be fitted with a label in the front and rear of the cubicle, indicating the panel
designation, rating and duty. Each relay, instrument, switch, fuse and other devices shall be
provided with separate labels.
Necessary wiring diagram shall be provided considering starting interlock, trip circuit, starting and
running mode signal.
It shall be possible to manually start the motor locally from the starter panel or in Auto mode
through PLC.
10.12 Variable Frequency Drives (VFD)
AC induction motor in clear water pumping station for rural distribution shall be coupled with a
Frequency drive of rating commensurate with the rated motor.
The Frequency drives shall be of Current Source Inverter Pulse Width Modulated (CSIPWM) with
GTO/IGBT/IGCT/SGCT/DTC technologies or later version, which performs precise speed and
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torque control of standard squirrel cage motors with optimum efficiency. Each drive must have a
soft starting feature and a by pass arrangement for DOL starting of motors. All frequency dives
shall be suitable for data connectivity with PLC/SCADA system and shall have Ethernet
TCP/IPsuitable communication 99 port and protocol. The drives must be easily programmable. The
drives shall be provided with surge protection, programmable lockable code. The Frequency drive
shall have following characteristics:
o Accurate open loop torque control

o Torque step rise time typically less than 5 ms
o Speed control inaccuracy typically 0.1% to 0.5% of nominal speed
o 150% overload capacity for 60 second
o Total Harmonic distortion shall comply with the provisions of IEEE 519. Necessary
metering, self-diagnostic arrangement (including display and alarm facilities) shall be
provided for local/ remote monitoring.
 Technical Parameters
o Main connection
 Voltage : 3 phase, 415 +/- 10 % permitted tolerance
 Frequency : 45 to 65 Hz, maximum rate of change 17%/s
 Imbalance : Max. +/- 3% of nominal phase to phase input voltage
 Fundamental Power factor : 0.97 (at nominal load)
o Motor connection
 Voltage : 3 phase, from 0 to applied incoming supply voltage, 3-phase
 symmetrical
 Output Frequency : 0 to 250 Hz
 Frequency Resolution : 0.01 Hz
o Continuous Current : 1.0 * I2N(normal use)
o Short Term Overload
o Capacity (1min./10min)
o : I2max = 1.1 * I2N
o Field Weakening point : 8 to 300 Hz
o Acceleration Time : 0 to 1800 sec
o Deceleration Time : 0 to 1800 sec
o Efficiency : Min. 97% at nominal power level
o Environment limits
o Ambient temperature : 0 to 45 deg. Cent.
o General Standard Control Connections or as per Process Requirement
o 3 programmable differential analogue inputs (1 voltage signal, 2 current signals)
o 7 programmable digital inputs
o 2 programmables analogues outputs (current signal)
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o 3 programmable digital outputs (from C relays)
o Power Torque Speed value must be configurable to the etherrnet tcp/ip port for their remote
data acquisition in PLC/ SCADA. Optional analogue and digital extension modules can be
added as well as a wide range of field bus adapters.
o Protection
 Over current
 Short circuit at start-up
 Input phase loss
 Output phase loss
 Motor overload
 Earth fault
 Overvoltage
 Undervoltage
 Over temperature
 Motor stall
o Application macros
The features a selection of built-in, pre-programed application macros for configuration of

inputs, outputs, signal processing and other parameters. It shall have interfacing facilities
to communicate data to SCADA system. These include:
 FACTORY SETTING for basic industrial applications

 HAND/AUTO CONTROL for local and remote operation
 PID CONTROL for closed loop processes
 TORQUE CONTROL for process where torque control is required.
 SEQUENTIAL CONTROL for processes where torque control is required.
 USER MACRO 1 and 2 for user’s own parameter setting
 Comprehensive testing and diagnostic function
o Tests
 Each unit of Variable frequency drive shall be tested at the manufacturer’s work with
the motor they have been assigned to work for at the STP
 Test result must satisfy the efficiencies on various loads and at different frequency
levels against their quoted values.
Contactor : Air break

Pole configuration : Three pole / Four Pole as per data sheet
Auxiliary contacts : 2 NO + 2 NC
Utilisation category : As per data sheet
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CT : Cast resin type
Ratio, class & Burden : As per SLD / Data sheet
Insulation class : 1.1 kV
Control Transformer : Cast resin type

Voltage Ration : 415 / 110 V AC
Insulation class : 1.1 kV
Rating : 1000 VA
Capacitor
Type : Dry type, Mixed Di-electric versions with self-healing capacity
conforming to IS 13340.
Voltage : 220 Volts to 575 Volts based on application
Push button Actuators

Type : Panel door mounted – shrouded type for START and Mushroom
type for STOP / RESET
Contact ratings : 5 Amps
10.13 6.6/3.3/1.1 kV XLPE cable
10.13.1 Scope
This part of the specification covers the requirements of design, manufacture, inspection, testing
and supply at site of 6.6/3.3/1.1 kV grade XLPE power and control cables.
10.13.2 Standards
The 6.6/3.3/1.1 kV grade Power & Control Cables conform to the requirements of the latest
Indian Standard Specifications including but not limited to the following:
IS 7098 : Cross-linked polyethylene insulated PVC sheathed cables

IS 3975 : Mild steel wires, strips and tapes for armouring of cables
IS 10418: 1982 : Drums for electric cables.
IS 10810 : Methods of test for cables
IS 1554 (Part I) : PVC Cables for voltage up to and including 1100 volts
IS 8130 : Conductors for insulated electric cables
IS 5831 : PVC insulation and sheath of electric cables
IS 3975 : Mild steel wires, strips and tapes for armouring of cables
10.13.3 General construction
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The cables shall be suitable for laying in trays, trenches, ducts, conduits and buried underground
installation with uncontrolled backfill and possibility of flooding by water. These shall have
following constructional features.
All power and control cables for use on medium & low voltage system shall be of 6.6/3.3/1.1 kV
grade with aluminium / copper conductor, XLPE insulated, PVC inner sheathed, armoured and
overall PVC sheathed.
The construction of the conductors shall be SOLID for aluminium conductor cables up to 10 mm
sq. and for copper conductor cables up to 2.5 mm sq. For cables above 10 mm sq. and for copper
cables above 2.5 mm sq. the conductor shall be STRANDED. Conductors of nominal cross
sectional area less than 10 sq.mm shall be circular only. Conductors of nominal cross section
area 16 sq.mm and above may be circular or sector shaped.
The core insulation shall be with XLPE applied over the conductor by extrusion and shall conform
to the IS 7098. Control cables having 6 cores & above shall be identified with prominent &
indelible numerals on the outer surface of the insulation. Colour of the numbers shall be white
with a spacing of maximum 500 mm between two consecutive numbers.
The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of type ST2 PVC compound per IS 5831. The extruded inner
sheath shall be of uniform thickness of size not less than 0.5 mm up to 16 sq.mm, 0.8 mm from
25 sq.mm upto 120 sq.mm and 1.0 mm above 120 sq.mm conductor size. Taped inner sheath
shall also be acceptable.
For multi core cables, the armouring shall be by single round galvanized steel wires where the
calculated diameter below armouring does not exceed 13 mm and galvanized steel strips where
this dimension is greater than 13 mm. Requirement and methods of tests for armour material and
uniformity of galvanization shall be as per IS 3975 and IS 2611.
The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound and
conforming to the requirements of type ST 2 compound per IS 5831. To protect the cables against
rodent and termite attack, suitable chemicals shall be added into the PVC compound of the outer
sheath.
The dimensions of the insulation, armour and outer sheath materials shall be governed by values
given in IS 1554 (Part I).
10.13.4 Packing
The cables shall be supplied in standard drum lengths duly wound on non-returnable wooden
drums.
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Vendor shall ensure that the bending radii of cables are not less than 12 times their overall
diameters when wound on drums. Both ends of the cables shall be sealed.
Following information shall be printed on the flange of each cable drum.

a) Type
b) Size
c) Voltage grade
d) Length in meters
e) ISI Mark
f) Gross weight
g) Direction of rolling
10.14 Specification for power / lighting distribution boar ds
10.14.1 Scope
This part of the specification covers the requirements of design, manufacture, assembly,
inspection, testing and delivery at site of Power/ Lighting Distribution Boards / Panels.
10.14.3 Standards
The Power / Lighting Distribution Boards shall conform to the requirements of the latest Indian
Standard Specifications including but not limited to the following:
IS 13947 : Low Voltage Switchgear and Control gear

IS 11353 : Guide for Uniform System of marking and identification of conductors and
apparatus
IS 2705 : Current Transformers
IS 8623 : Low voltage switchgear and control gear assemblies
IS 4237 : General requirements for switchgear and Control gear for voltages not exceeding
1000 V
IS 13032 : Miniature air-break circuit breakers for voltages not exceeding 1000 V
IS 13947 : Switches, disconnectors, air break Switch (Part 3) disconnectors and fuse
combination units
IS 13703 : LV Fuses for voltages not exceeding 1000 V ac or 1500 V dc Part 1 General
requirements
IS 1248 : Direct acting electrical instruments
IS 722 : AC Electricity Meters
10.14.4 Construction & component specification
The boards shall be sheet steel enclosed on all sides and shall be dust and vermin proof, providing
a degree of protection equivalent to IP 54. The sheet steel used shall be 14/16 Gauge CRCA.
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The distribution boards shall be provided with hinged doors for access to components. Doors
shall be provided with gasket all around with neoprene gaskets.
The Power Distribution Boards (PDBs) / Lighting DB, shall be suitable for wall mounting. Cable
entries to these boards for incoming as well as outgoing cables shall be from the Top The bus
bars of Power Distribution Boards (PDBs) / Lighting DB shall be of electrical grade Copper of
adequate size. These shall be supported on SMC/ DMC/ Epoxy non-hygroscopic supports at
suitable intervals to withstand the thermal and dynamic stresses developed due to short circuit
current of 10KA for Power DBs & Lighting DB.
Internal Earth bus of adequate size of copper flat shall be provided extending through the entire
length of the boards
10.14.5 Earth Leakage Circuit Breakers (ELCBs)
The ELCBs shall be designed to operate within 30 milliseconds to provide effective protection
against electrocution risks and fires caused by earth leakage faults of 30 mA and above. All parts
of the switching mechanism shall be of non-corroding self-lubricating material thus providing
consistent and trouble free services. These shall have short circuit withstand capacity of 10 KA.
10.14.6 Miniature Circuit Breakers
These shall be hand operated type. The miniature circuit breaker shall incorporate thermal
overload and magnetic short circuit tripping devices. These shall have short circuit withstand
capacity of 10 KA.
Provide positive ‘ON’ locking devices for miniature circuit breakers supplying power to corridor
lights, night lights and other circuits requiring continuous supply.
Provide a neatly typed directory on each panel, listing the locations of devices and equipment
served by each circuit, mounted on the inside of the front cover in a frame with hard transparent
shield.
10.14.7 Internal wiring
The boards/ panels shall be supplied completely wired, ready for the external connections at the terminal
blocks. Wiring shall be carried out with 1100V grade PVC insulated, stranded copper conductor of
adequate size (min. 2.5 mm sq.) Identification ferrules shall be provided to correspond with wiring
diagrams. All wiring shall be terminated on terminal block. Terminals of Power Distribution Boards
/ Lighting DB shall covered terminals.
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10.14.8 Painting
Sheet metal work of the Boards / Panels shall undergo a thorough surface treatment comprising rust
removal, degreasing, pickling and phosphating prior to painting. The pre-treated boards/ panels
shall be painted / Powder coated with two coats of suitable primer and finished with two coats of
Power coated of approved shade as per IS-5.
10.15 Specification for cable carrier / cable containment system and accessories
10.15.1 Scope
This part of the specification covers the requirements of design, manufacture, assembly,
inspection, testing and delivery at site of cable carrier / cable containment system with
accessories.
10.15.2 Standards
The Cable carrier system with accessories shall conform to the requirements of the latest Indian
Standard Specifications including but not limited to the following:
IS 513 : Cold rolled low carbon steel and strips

IS 1079 : Hot rolled carbon steel and strips.
IS 2629 : Recommended practice for hot dip galvanizing
IS 2611 : Methods for testing uniformity of coating of Zinc coated articles
IS 1367 : Technical supply conditions for threaded steel fasteners.
IS 1663 : Method for tensile testing of steel sheet & strip of thickness 0.5 mm to
3 mm
10.15.3 Construction
Cable carries, fittings and accessories shall be fabricated out of rolled Mild Sheel sheets free from
flaws such as laminations, rolling marks, pitting etc. conforming relevant codes.
Minimum thickness of Mild Steel sheets used for fabrication of cable carries and fittings shall be
1.60 mm up to 450 mm wide trays and 2.0 mm above 450 mm wide trays. The thickness of side
coupler plates shall be minimum 3 mm.
All accessories like bends, reducers, tees, crosses coupler plates, etc., shall be pre-fabricated and
not fabricated at site.
Structural supports shall be made out of Mild steel with hot dip galvanized of adequate size and
load carrying capacity.
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Structural supports shall be located appropriately and the distance between any two supports shall
not be more than 1500 mm.
In RCC trenches, the cable carriers shall be of cantilever construction and erected with anchor
fasteners / insert plate with adequate load carrying capacity. Fittings like bends, reducers, tees,
crosses, etc. accessories like side coupler plates etc. and hardware GI bolts, nuts, springs, washers
as may be required shall be treated as part of the supply item.
In masonry brick work the cable carrier support shall be grouted adequately with appropriate
supports using cement mortar.
In vertical sections the cable carriers shall be of ladder / perforated construction with one or multi
tiers complete with matching fittings like bends, reducers, tees, crosses etc., accessories like side
coupler plat etc. and hardware GI bolts, nuts, springs, washers, etc. as may be required.
The standard length of each size and type of cable tray / ladder shall be not more than 2.5 metre.
10.15.4 Support system for cable carriers
The support system shall be fabricated from standard structural steel members. The cable carriers
and support system shall be hot dip galvanised
10.15.5 Galvanizing
Galvanising of steel components and accessories shall conform to relevant code The galvanising
shall be uniform, clean, smooth, continuous and free from spots. Should the galvanizing of the
samples be found defective, the entire batch steel shall have to be re-galvanised at
Concessionaire's cost after pickling.
The amount of zinc deposit over threaded portion of bolts, nuts, screws a washers shall be as per
relevant codes. The removal of extra zinc on threaded portion of components shall be carefully
done to ensure that the threads have the required zinc coating on them.
The hot dip galvanized thickness shall not be less than 80 micron thickness.
10.16 Earthing and Lightning Protection System

Earthing and lightning protection system shall comply with the following International Standards,
including those referred to therein: ANSI / IEEE Std. 80 and 142, IEC 61024 and IEC-62305, 3043.
Designing the earthing and lightning protection systems as per the applicable standards and specific
design basis listed below:
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a) Average value of soil resistivity as measured for different electrode spacing, at site. (from
2 to 100 Meter or more in steps of 5, 10 Meter. At least 20 nos. readings shall be taken over
the plant area, each in two different directions)
b) Permissible values of step and touch potentials based on weight of human being as 70 kg
and Earth fault current of 40 kA for 1 seconds
c) Gravel with surface resistivity of 3000 ohm-m
d) Depth of burial of earth conductors of 600 mm below ground level
e) Ground resistance with only electrodes of maximum 1 ohm.
f) Ground resistance of earthing grid of maximum 1 ohm
g) Corrosion allowance of at least 20 %
h) Earthing conductor material shall be minimum 20 mm diameter and 3 m long GI Pipe.
Earthing and lightning protection system shall be provided to ensure equipment safety, personnel
safety and to facilitate designed operation of protective devices during earth fault conditions in the
associated system.
The Concessionaire shall install bare earth conductors as required for the system and individual
equipment earthing. All the work such as cutting, bending, supporting, drilling, brazing /
soldering/welding, clamping, bolting and connections to structures, equipment frames, terminals or
other devices shall be in the Concessionaire’s scope. All hardware and consumables such as fixing
cleats / clamps, anchor fasteners, lugs, bolts, nuts, washers, brazing electrodes, flux, bituminous
compound, anti-corrosive paint, etc. as required for the complete work shall be included by the
Concessionaire.
Tap connections (earthing leads) of more than 500 mm long, from main earthing grid to equipment
shall be embedded in the floor by the Concessionaire together with associated civil work such as
chipping / chasing, concreting and surfacing, etc. The concrete cover over the conductor shall not
be less than 50 mm.
The scope of installation of earth conductors in outdoor areas, buried in ground shall include
excavation in earth up to 600 mm depth and 400mm width, laying of conductor at 600 mm depth,
brazing as required of main grid conductor joints as well as riser’s up to 500 mm above ground at
required locations and backfilling. Backfilling material to be placed over buried conductor shall be
free from stones and other mixtures. Backfill shall be placed in layers of 150 mm, uniformly spread
along the trench and compacted. If the excavated soil is found unsuitable for backfilling, the
Concessionaire shall arrange for suitable material from outside. Earthing conductors in outdoor
areas shall be laid 1500mm away from buildings. The scope of installation of earth conductors in
outdoor areas buried in ground, shall include excavation of earth up to 600 mm depth, brazing /
welding of main grid conductor, joints as well as risers of length 500 mm above ground at required
locations and then backfilling.
Wherever earthing conductor crosses underground service duct and pipes, it shall be laid 300 mm
below them. If the distance is less than 300 mm, the earthing conductor shall be bonded to such
service ducts / pipes.
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The scope of installation of electrodes shall include installation of electrodes in constructed earth
pits, and connecting to main buried earth grids. The scope of work shall include excavation,
construction of the earth pits including all materials required for treatment (salt, charcoal,
chemicals, etc.), placing the electrode and connecting to main earth grid conductors.
The work of embedment of earthing conductor in RCC floors / walls along with provision of earth
plate inserts / pads / earth risers shall be done by the Concessionaire preferably before the floors /
columns / walls are cast. The embedded conductors shall be connected to reinforcing rods wherever
necessary.
The scope of installation of earthing leads to the equipment and risers on steel structures / walls
shall include laying the conductors, brazing / cleating at specified intervals, brazing to the main
earth grids, risers, bolting at equipment terminals and coating brazed joints by bituminous paint.
Earthing and lightning protection system conductors along their run on walls / columns, etc. shall
be cleated at an interval of 750 mm.
Main earthing conductor shall be buried below the trench at crossing points.
Metallic frames of all electrical equipment shall be earthed by two separate and distinct leads and
then connected with earthing system.
Neutral of a transformer shall be earthed to two separate earth electrode pit by two separate earth
leads.
Crane rails shall be connected to the earthing system.
An earthing mat shall be provided under the operating handle of the disconnector. Operating handle
of the disconnector and the supporting structure shall be bonded together by a flexible connection
and connected to earth grid.
Metal pipes and cable conduits shall be effectively bonded and earthed by earthing clamps
efficiently fastened to the conduit at both ends.
Neutral connection shall never be used for equipment earthing.
A separate earth electrode shall be provided for each lightning arrester and for each lightning
conductor down comer.
Cable sheaths and screen shall be bonded to the earthing system.
Armour of multicore cables shall be bonded to earthing system at both ends, while that of single
core cables shall be earthed at source end only. The size of conductor for bonding shall be
appropriate with the system fault current.
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Conduits, fixtures, junction boxes, etc. shall be bonded to the earthing system by 16 SWG diameter
copper wire looped from lighting panel earth bus onwards. Outdoor lighting poles, junction boxes,
etc. shall be earthed by 12 SWG copper wires.
Street light pole and junction box shall be earthed with 12 SWG tapped off from the 25x3 mm GI
earthing conductor to be laid along the street lighting cable.
All metallic parts such as transformer, fence, gate, etc. shall be properly earthed.
Wherever earthing conductor passes through walls, galvanized steel pipe sleeves shall be provided
for the passage of earthing conductor. The pipe ends shall be sealed by the Concessionaire, by
suitable water-proof compound. Water stops shall be provided wherever earthing conductor enters
the building from outside below ground level.
All connections in the main earth conductors buried in earth / concrete shall be brazed type.
Connections between main earthing conductor and earth leads shall also be of brazed type.
Connection between earth leads and equipment shall be by two bolts.
Installation of lightning conductors on the roof of buildings shall include laying, anchoring,
fastening and cleating of horizontal conductors, grouting of vertical rods wherever necessary,
laying, fastening / cleating / brazing of the down comers on the walls / columns of the building and
connection to the test links to be provided above ground level.
Lightning protection system down-conductors shall not be connected to the conductors of safety
earthing system above ground level. The lightning protection system for the structures shall be
installed by forming a grid of exposed continuous earth conductors and taking down-comers along
the walls/supports of the structure and terminating the same at earth pits. A separate earth electrode
shall be provided for each lightning arrester and for each lightning conductor downcomer. The
lightning protection system earth pits shall be inter-connected to form the safety earthing grid
provided for the building / structure. The safety earthing grid shall be connected to the mains grid
of the switch yard.
The lightning protection air termination rods and / or horizontal air termination conductors shall be
fixed in a firm manner. The necessary accessories such as cleats, clamps, brazing materials, bolts,
nuts, shall be supplied by Concessionaire.
Air termination systems shall be connected to earthing system by down conductors. There shall not
be any sharp bends, turns and kinks in the down conductors.
All joints in the down conductors shall be of brazed type. All metallic structure within 1 meter of
down conductors shall be bonded to lightning protection system.
Every down conductor shall be provided with a ‘test link’ mounted on wall / column at about 1000
mm above ground level housed in a 16 SWG GS enclosure. The test joint shall be directly connected
to the earth electrode.
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The lightning protection system shall not be in direct contact with underground metallic service
ducts, cables, cable conduits and metal enclosures of electrical equipment. However, all metal
projections, railings, vents, tanks, etc. above the roof shall be bonded together to form a part of roof
grid.
Lightning protection system down conductors shall not be connected to other earthing conductors
above ground level. In addition, no intermediate earthing connection shall be made to lightning
arresters and transformer, whose earthing leads shall be directly connected to electrode pit.
o
10.16.1 Earth electrodes and pit
Treated earth pits shall comprise of treatment material such as salt and charcoal or any other
conductivity enhancing compound. Treatment material placed around the electrode shall be finely
graded, free from stones and other harmful mixtures. Backfill shall be placed in 150 mm thick
uniformly spread and compacted layers. If excavated soil is found unsuitable for backfilling, the
Concessionaire shall arrange for a suitable soil from outside.
Earth electrodes shall be fabricated from minimum 20 mm diameter, 3m long, copper rod or 40
mm diameter, 3m long GI pipe. The minimum spacing between adjacent electrodes shall be 6 m.
Electrodes shall, as far as practicable, be embedded below permanent moisture level.

Test pits with concrete covers shall be provided for periodic testing of earth resistance. Installation
of electrodes in test pits shall be suitable for watering. The necessary materials required for
installation of test pits shall be supplied and installed by Concessionaire. The installation work shall
also include civil works such as excavation / drilling and connection to main earth grid. Earth
electrode pit marker shall be provided.
Treated earth pits shall be treated with suitable treatment material mentioned above, if average
electrical resistivity of soil is more than 20 ohm meter.
Conductor size for connections to various equipments shall be as per the table as follows:
Equipment Conductor Size

Motors Up to 11 kW 8 SWG GI wire
11 kW up to 22 kW 4 SWG GI wire
22 kW up to 37.5 kW 25 x 3 mm GI flat
37.5 kW to 90 kW 25 x 6 mm GI flat
90 kW to 200 kW 40 x 6 mm GI flat
Above 200 kW 50 x 10 mm GI flat
PCC 50 x 6 mm GI flat
PDB 50 x 6 mm GI flat
DG and other panel 50 x 6 mm GI flat
Local control station, street light 8 SWG GI wire
pole and its junction box
All switchyard equipment 50 x 6 mm GI flat
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Equipment Conductor Size
Main earth grid 50 x 6 mm GI flat
Lighting Panel 25 x 3 mm GI flat
Indoor fixtures 14 SWG GI wire
All paint, scale etc. shall be removed before earthing connections are made.
Anchor bolts or fixing bolts shall not be used for earthing connections.
10.17 Lighting System Equipment

Lighting system shall comply with the following International Standards, including IEC 60083,
60598, 60669, 60884, 60906 and 60947/other applicable code & guidelines.
General Requirements
Lighting system equipment shall cover lighting panels, lighting fixtures, switches, receptacles with
switches, for outdoor lighting - lighting masts, street lighting poles, etc.
Normal and emergency lighting for indoor and outdoor areas shall be provided.
The Concessionaire shall provide emergency lighting in the vital installation including pump house,
switchboard room, office building, administration areas, etc. 10% of the total normal lighting shall
be emergency type.
Galvanized conduits shall be used for all exposed wiring and PVC conduit for concealed wiring
conforming to CPWD standard “General Specifications for electrical works , part 1 Internal –
revision 2013”. Minimum size of conduit shall be 20 mm / 25mm for exposed / concealed conduits
respectively. Wiring inside the pump house, switchboard room and other areas shall be concealed
type.
Wires used for conduit wiring of lighting fixtures / ceiling fans and receptacles shall be 250/440V
grade, PVC insulated, single core, stranded copper conductor wires of sizes not less than 2.5 sq.
mm and 4 sq. mm respectively. Wires shall conform to IS standards. Three individual wires with
proper color coding (P-N-E) shall be used for wiring and no joint in wires between conduit is
allowed. 3 core x 2.5 sq. mm. copper cable shall be used for circuiting of peripheral lighting.
Lighting panels
Lighting panels shall be of wall mounting type and fabricated out of 1.6 mm. thick cold rolled sheet
steel. lncomer circuit shall be controlled by a switch disconnector with a link in the neutral circuit.
Outgoing circuits shall be controlled by single pole MCBs of minimum 10A rating and a link in
the neutral circuit. TPN MCB shall be provided for street lighting/ area lighting purposes. Breaking
capacity of MCBs shall not be less than 10 kA. Residual circuit breakers (RCCBs) shall be used on
all lighting and receptacle circuits.
It shall be possible to terminate incoming and outgoing circuits from top and bottom. Knock-out
for cable / conduit entries for all the circuits shall be provided. Separate circuits shall be provided
for control of lighting fixtures and receptacles. Each phase shall have at least one spare circuit.
495
The panel shall be provided with 3 phase and neutral copper busbar adequately rated to cater to the
requirement of all the outgoing circuits. Two earthing terminals shall be provided external to the
panels for terminating the external earthing conductor.
The panel shall be internally wired using color coded, stranded copper conductor, PVC insulated
wires of 1100 V grade.
The panels shall have hinged door, gasketed all round and provided with handle lock. Operation of
incomer switch or MCBs shall be possible without opening the door.
Detailed specification of lighting panel and its accessories (e.g. busbar, MCB, indicating
instrument, indicating lamp, etc.) are described at MV and LV switchboard.

Lighting fixtures and its accessories
Lighting fixtures for illumination of outdoor and indoor areas shall be supplied. Fixtures for outdoor
installation shall be of weatherproof design with degree of protection of IP66. The fixtures shall be
suitable for operation on a nominal supply of 240 V, single phase, 50 Hz, AC with a voltage
variation of + 3 %.
Fixtures shall be complete with internal wiring, lamp, holder, ballast, reflector, louvres / perspex,
etc. as required for their satisfactory operation. Fixtures shall be energy efficient and ballast shall
be electronic low loss type. All indoor lighting fixture for office and control room shall be
decorative type and for remaining areas it shall be industrial type.
The power factor of the luminaries shall be maintained at 0.95.
LED lamp shall be ‘Tri-band” color temperature of the luminaire shall be in the range of 5000 k –
6000k (CCT as per BIS).
Lighting fixture reflectors shall generally be manufactured from steel or aluminum sheet of not less
than 20 SWG thickness. Each fixture shall be complete with a four-way terminal block for
connection and looping of incoming and outgoing cables. Each terminal shall be able to accept two
2.5 mm2 copper stranded conductors. Each lighting fixture shall be provided with an earthing
terminal suitable for connecting 16 SWG copper stranded conductor. All metal or metal enclosed
parts of the housing shall be bonded and connected to the earth terminal to ensure satisfactory
earthing continuity throughout the fixture. All reflectors and louvers shall be finished to the same
standard as the fixture housing.
The enamel finish shall have a minimum thickness of 2 mils for outside surface and 1.5 mils for
inside surfaces. The finish shall be non-porous and free from blemishes, blisters, and fading.
Size of wire chosen shall be such as to limit the voltage drop to within 3 %. Minimum area of
conductor shall be 1.5 sq mm stranded copper for lighting and 2.5 sq mm / 4 sq mm for 5A / 15A
receptacle circuits respectively, and current density shall not exceed 2.5 A/sq mm. Generally, not
more than 8 to 10 lighting points shall be wired in one circuit. For calculating connected loads of
496
various circuits, a multiplying factor of 1.25 shall be assumed on the rated lamp wattage for sodium
vapour and fluorescent lamp fixtures to take into account the losses in the ballast. A loading of 100
watts and 500 watts shall be assumed for each, single-phase 5 amps and 15 amps receptacles
respectively. Wires belonging to different phases shall not be run in the same conduit. However,
more than one circuit on the same phase can be run in the same conduit. For every phase wire, a
separate neutral wire shall be run. Neutral wire for different phases shall not be looped.
The following types of fixtures shall be considered for various areas. The construction features are
indicative. Equivalent or superior feature is acceptable.
General purpose flood lighting fixtures - Housing with integral control gear from die-cast aluminum
alloy, vitreous enameled, and with electrochemically brightened anodized aluminum reflector,
clear, heat resistant glass with rubber gasket secured to housing by a ring, cast iron base and MS
cradle for turning in horizontal and vertical planes and lockable in desired position, suitable for
max. 3000 W LED lamp. These fixtures shall be used for illumination of outdoor area for providing
general illumination.
Gate post lights - Top canopy spun from aluminum sheet and vitreous enameled. Spigot shall be
made of die-cast aluminum and vitreous enameled. Fixture shall be suitable for 70 W HPSV/MH
lamp.
Fluorescent tube fixtures - Housing made from mild steel sheet and stove enameled white. Reflector
assembly made from electrochemically brightened anodized aluminum sheets secured to housing
with spring loaded triggers and suitable for 2/3 nos. 36 watt triphosphor coated tubes. These fixtures
shall be used in switchboard room and other areas. Where false ceiling is provided, fixtures shall
be suitable for recessed mounting. For non-false ceiling office areas, decorative type fixtures shall
be used.
Lighting fixture used for pump house and other areas with high ceiling shall be medium/high bay
type suitable for 150/250/400 W LED lamps. These shall have housing with integral control gear
of from die-cast aluminum alloy, electrochemically brightened anodized aluminum reflector, etc.
1200mm sweep ceiling fans shall be provided in areas such as offices, etc. as per design
requirement. Adequate ventilation arrangements shall be made for enclosed areas where ceiling
fans are not proposed to be installed or cannot be provided. Power supply for the ceiling fans shall
be derived from lighting circuits. Ceiling fans shall be complete with all accessories. Regulators
shall be electronic (triac) type.
The work shall comprise wiring in heavy gauge (minimum 16 SWG) GI conduits, fixed and
supported at intervals of 300 mm on walls, ceiling etc.; installation of light control switches and
receptacles housed in GS boxes; earthing with 16 SWG copper wire run along the conduit and
clamped to it at every 300 mm; and termination of cables/wires at lighting panels, light control
switches, receptacles, lighting fixtures etc., as required. The minimum size of conduit shall be 20
mm. Space factor (ratio of total wire area to internal conduit area) shall be 40 %. Concealed
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conduiting shall be provided to all building / office areas. For pump house area, the Concessionaire
shall adopt surface conduiting also.
Receptacles and Switches – It shall be weather-proof for outdoor application. For Pump-house area
and Switchgear room, industrial type receptacles with switch shall be provided. For Office areas,
it shall be decorative type. 3 phase welding receptacles shall also be provided as per requirement.
The lighting poles for streetlights shall be of tubular / swaged type steel poles, circular in
construction. The steel poles shall be coated with bituminous preservative paint on the inside as
well as embedded outside surface. Exposed outside surface of the steel poles shall be painted with
one coat of red lead oxide primer. After completion of installation, two coats of aluminum paint
shall be applied. The supply of poles shall be complete with fixing bracket, necessary pipe reducer
for fixing the fitting and also include the necessary associated pole mounted junction boxes. 2 nos.
studs shall be provided on the pole for earthing. The lighting poles shall have an end cap with
brackets for mounting HPSV/MH lamps (of suitable wattage) in weatherproof fittings, cut-off type
or semi- cut off type luminaries. The brackets shall be welded to the pole and shall ensure an
suitable overhang depending on height of the pole.
Junction boxes with terminals shall be supplied for branching and terminating the lighting cables,
weatherproof and suitable for usage in outdoor areas. The junction boxes shall be dust and vermin
proof and shall be fabricated from 2 mm CRCA sheet steel and shall be complete with removable
cover plate with gaskets, two earthing terminals each with nut, bolt and washer. The Concessionaire
shall provide support arrangement (through 25 x 4 mm GI flat U clamp) for proper fixing of the
junction box to the pole.
The boxes shall be hot dipped galvanized / painted with on shop coat of red oxide zinc chromate
primer followed by a finishing coat of paint. Suitable rubber gaskets shall be provided on the doors
of the junction boxes. The junction boxes shall have a locking facility, suitable to be opened by a
common panel key for all the junction boxes. The boxes shall have provision for mounting on the
poles. Suitable knockouts for the entry for cable / conduit entry shall be provided with terminal
blocks, HRC fuses etc.
The terminal blocks shall be mounted securely on brackets welded to the back sheet of the box.
The terminals shall be 1.1kV grade, one piece construction complete with barriers, galvanized nuts,
bolts, washers and provided with identification strips of PVC. The terminals shall be made of
copper alloy and shall be of box clamp type. Double compression brass glands shall be provided
for entry / exit of the cables into the junction box.
o Illumination Levels
Lighting system shall be designed to achieve the average maintained levels of illumination as
indicated below. The Concessionaire shall be required to measure the actual levels and carry out
necessary modifications to accomplish specified levels. It is to be noted that the values measured
after installation will exceed those specified due to inclusion of light loss factor in the calculation.
Measurement shall be carried out after 100 burning hours.
Area Illumination level (Lux)
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Pump House 300
Office/Conference Room 500
Switchboard Room 300
All other indoor areas 150
Outdoor plant area and Road 10 – 20
The illumination system shall be so designed that the uniformity factor is of acceptable level and
that the glare is within limits. The ratio of maximum to minimum illumination levels shall not
exceed 20 in outdoor area.
The following values of ‘light loss factor’ shall be considered for design:
a) Indoor air-conditioned area : 0.85
b) Other indoor areas : 0.85
c) Outdoor area : 0.85
The Concessionaire shall furnish detailed design calculations, uniformity factors, ratio of maximum
to minimum illumination levels, ratio of average to minimum illumination levels, glare values, etc.
for approval. Detailed characteristics of various types of fixtures including photometric curves and
tables shall also be furnished for review.
10.17.1 Receptacles with switches
Adequate number of receptacles of 6A, 16A and 32A rating with MCBs suitable for operation on
230 V AC, 1 phase, 50 Hz supply shall be provided as detailed below:
a) Decorative and industrial type shall be proposed in relevant areas.

b) Receptacles proposed for outdoor installation shall be of weatherproof design of degree of
protection IP65.
c) Single phase receptacle shall be provided with a switch / MCB of the same current rating, housed
in the same enclosure. Three phase receptacles shall be associated with a MCB of the same rating, housed
in the same enclosure.
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Section – G5.2
Technical specification for Diesel generator set
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Section G5.2: Technical specification for Diesel generator set
1. General
1.1 Scope of work
This specification covers the technical requirements and essential particulars for the Design,
manufacture, supply, inspection, testing and commissioning of adequate size of Diesel Generator
systems as covered in the specification documents and drawings. The Concessionaire shall
demonstrate that the DG set satisfies the requirements of the specification and applicable codes
2. Diesel Generator
2.1 Applicable codes and standards
2.1.1 The DG set shall conform to the latest editions of the codes and standards listed under Clause 2.1.2
below & other applicable standards. Nothing in this specification shall be construed to relieve the
Concessionaire of this responsibility.
2.1.2 The applicable Indian standards and codes shall be followed wherever applicable for the DG set.
In all cases, the latest revision of the standards shall be referred to. In the event of conflict between
any of these Specifications and the Codes referred, such specifications shall be defined, prepared
by the Concessionaire and submitted to the Project Engineer for approval. The decis ion of Project
Engineer in such case shall be final and binding on the Concessionaire. The following standards,
unless otherwise specified herein, shall be referred to.
IEC 34 Rotating electrical machines

BS 5000 Part 3 Reciprocating IC engines: Performance
IS 10002 Performance requirements of Diesel Engines
IS 10000 (OR) Equivalent BS Method of tests for IC engines
code
BS 5514 / (ISP 3046) Reciprocating internal combustion engines performance standard
reference conditions, declarations of power, fuel and lubricating
oil consumptions and test methods
IS : 2147 Degree of protection provided by enclosure for low voltage
switchgear and control gear
IS : 4722 Rotating Electrical Machines
IS : 3043 Code of practice for earthing
IS 8623 Low voltage switchgear & control gear assemblies
IS 5578 Marking of insulated conductors
IS 11353 Uniform system of marking & identification of conductors and
apparatus
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IS 2705 Current Transformers
IS 7098 Cross linked polyethylene insulated (XLPE) PVC sheathed cables,
Part 1: For working voltage up to and including 1100 V
IS 3156 Voltage transformers
IS 5082 Material data for aluminium bus bar
IS 1248 Direct acting electrical indicating instruments
IS 9224 Fuses with high breaking capacity
IS 13947 Low voltage switchgear & control gear
IS 13364 Specification for ac generators driven by Part 2, reciprocating
internal combustion engine rated above 20 kVA and up to 1250
kVA
IS 3231 Specification for electrical relays for power system protection
IS 8686 Specification for static protective relays
IS/ IEC 60947 Low-voltage switchgear and control gear
3. Construction & component specification
3.1 Diesel Engine
3.1.1 The diesel engines shall be approved make, suitable for Prime power rating, direct
injection, four stroke, multi cylinder, water cooled through base mounted radiator, turbo
charged, water cooled type operating, full acoustic enclosure & capable of developi ng
requisite BHP rating to drive the Alternator
3.1.2 The engine shall be designed to operate at 50° C ambient temperature without any de -
rating factor
3.1.3 The engine & the governing system shall conform to class -A1 governing as per BS 5514
and shall be suitable for Prime power rating generating application. The unit shall be
suitable for operation on High Speed Diesel Oil without any modifications.
3.1.4 The governing system of the engine shall be of the microprocessor based electronic type
suitable to control frequency variation within +/-4% for a sudden load change up to 70%
The governor shall ensure that the speed of the set is regulated within 1% of the nominal
speed under normal operating conditions
3.1.5 The engine shall be electric start and shall be suitable for batt ery assisted manual / auto
/ SCADA system starting. The design shall ensure that the starter will be automatically
released when the engine picks up speed beyond 60% of the rated speed.
3.1.6 All moving parts of the engine and other associated equipment shall b e provided with
guards to prevent accidental contact. The guard shall be designed to facilitate easy
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removal and reinstallation
3.1.7 The engine fitments shall include but not be limited to the following: -
i) Flexible coupling and flywheel with guard

ii) Air inlet system with Dry type air filter with clogged condition indicator & turbo
charger
iii) Fuel system complete with Fuel Pump, flexible hoses, primary & secondary fuel
filters with service indicator and manual priming pump.
iv) Exhaust system with dry manifold and residential silencer.
v) Lube oil system with gear type oil pump, oil cooler, filter and crank case heater.
vi) Cooling system with engine coolant belt, fan, guard, radiator & low coolant level
switch.
vii) 24V D.C. Starter and battery charging alternator with auto cu t off.
viii) Acoustic enclosure suitable for outdoor operation
4. Alternator
4.1 The Alternator shall be industrial type, 1500 RPM, 6.6kV / 3.3kV / 415V, 3 Phase,
neutral, 50Hz, adequate size of DG set in KVA, 0.8PF, star connected, IP -23, horizontal
foot mounted, continuous duty suitable for prime power alternator, double bearing, self -
excited, self-regulated, brushless excitation machine with exciter and automatic voltage
regulator (AVR). The exciter shall be rotating diode type and Class 'H' insulated. The
exciter shall be capable of forcing the field for 3 seconds (or duration as specified in the
data sheet) in the event of short circuit fault at generator terminal. The exciter should be
capable of building up voltage from residual magnetism, protection against l ow speed
operation & high motor starting capability. The rectifier shall have in built protection for
over voltage and rate of rise of voltage. The generator shall have on line greasing facility
with grease nipple & relief device. All other parameters shal l be as specified in the data
sheet and conforming to codes and standards specified in the data sheet or relevant
standards.
4.2 Continuous damper winding fitted on each pole.
4.3 Thermistor for Hot spot detection with control unit for mounting in the control pa nel.
4.4 Terminal box with separately mounted adopter box having bus bars and flexible wiring
between Alternator terminals and adopter box drawn in PVC covered metallic flexible
conduit. The adopter box shall be suitable for terminating adequate size of 2 runs x 3½
core XLPE armoured Aluminium cable.
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4.5 The Alternator shall further meet the following specification.
4.6 The alternator shall conform to IS 4722 / BS standards.
4.7 The alternator shall be suitable for 20% over speed for two minutes.
4.8 The alternator terminal volt age for any load variation should be maintained within +/ -
2%.
4.9 The transient and steady state frequency variation should be limited to +/ -4% for sudden
load variation upto 70%. The generator TVD for sudden load variation of 100% shall not
be more than 15%.
4.10 Both ends of each phase winding shall be brought to the terminal box.
4.11 The alternator shall be capable of carrying 50% overload for a duration of one minute
and 10% overload for one hour in 12 hours operation.
4.12 The alternator shall withstand a 3 phase short circuit at the terminals for a period of 3
seconds
4.13 The total harmonic distortion shall not exceed 3% and the design shall permit up to 30%
unbalance between phases while in operation
4.14 The efficiency shall preferably not be less than 93% in the normal operating range of
50% to 100% loading
Driven equipment - adequate size as required

Output - adequate size as required
Terminal voltage - 6.6 kV / 3.3 kV / 415 volts under full load
conditions
Frequency - 50 Hz
No. of Phases - Three
Power Factor - 0.8 lag
Stator Connection - Star
Excitation - Brushless
Coupling - Direct
Operating duty - Continuous
Place of Installation - Outdoor
Class of Insulation - Class 'F'
Impedance - Confirming to IS
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Voltage Regulation - + / - 2.5% voltage regulation for a load
variation of full load to no load at 0.80 lag
power factor with AVR
Over Speed - All rotating part of alternator suitable for
120% over speed for two minutes
Excitation - AC Brushless static exciter of suitable

voltage and of adequate capacity to meet
the excitation current of the alternator at
full load at 0.80 power factor
5. Acoustic enclosure
5.1 The acoustic enclosure shall be of free standing, floor -mounting type integral with the
DG set.
5.2 The enclosure shall be provided with rugged heavy -duty structural steel base frame with
chequered plate flooring on which the DG set is to be mounted. The enclosure shall be
prefabricated factory-built and modular in construction.
5.3 The enclosure shall consist of acoustically treated panels housed in rugged steel frames,
which shall be bolted together to from the body of the enclosure.
5.4 Hinged doors shall be provided, on either side, which shall also be acoustically treated,
thereby providing easy access to the DG set while minimizing the operating space
requirements.
5.5 The construction of the acoustic enclosure shall be such that with both the acoustic doo rs
open on the either side, full access is available to the engine and alternator.
5.6 Fresh air inlet into the system a parallel baffle air inlet silencer shall be provided.
Additionally, to augment the fresh air inlet requirements, a forced air ventilation duct
with associated silencer shall be provided above the alternator.
5.7 For hot air discharge, an acoustic discharge plenum shall be provided in front of the
engine radiator, for discharge of hot air into the surroundings through a parallel baffle
air outlet silencer. The enclosure shall have suitable openings in the roof module for
exhaust piping.
5.8 The acoustic panels shall be filled with a special grade high -density mineral wool retained
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on the inside by perforated GI sheets specially designed for optimum sound attenuation.
5.9 The outer surface of the Acoustic Panels shall be fabricated of performed 16 G corrugated
CRCA sheet steel.
5.10 All structural members such as angles / channels used in the construction of the enclosure
frame.
5.11 All materials used for Acoustic Enclosure shall be fire resistant / fire retardant grade.
5.12 The sheet steel treatment shall consist of degreasing, de -rusting and phosphating followed
by two coats of zinc chromate primer, followed by two coats of Zinpholite surface for
superior corrosion resistance and two coats of finish paint.
5.13 For effective Acoustic sealing, necessary gasket material shall be provided.
5.14 All hardware and fittings used shall be passivated with zinc.
5.15 With the above Enclosure, the sound pressure levels when measu red at a distance of 1
meter outside the Acoustic Enclosure shall be confirming to the CPCB / Tamilnadu state
Pollution control Board regulation.
5.16 It shall be ensured that at least 1000 mm (min.) clear space is available all around the
Acoustic Enclosure to ensure free airflow for the Gen-set as required and to facilitate
accessibility for generator operation and routine maintenance.
5.17 The enclosure shall be provided with suction fans to ensure that the adequate cooling and
combustion air is made available to the engine and the temperature within the enclosure
is limited to 5° C above ambient.
5.18 The fan shall be designed with sufficient static to draw the requisite quality of air from
the duct provided for this purpose. Calculations shall be furnished to prov e the adequacy
of the ventilation system offered. The suction fans shall start automatically when the
temperature in the enclosure reaches 40°C and shall continue to run for 5 to 10 minutes
after the load is disconnected. A temperature controller shall be provided for this purpose
housed in sheet steel enclosure.
5.19 Two light points controlled by a switch complete with 36W fluorescent Luminaries and
lamps shall be provided. Provision shall also be made for fixing a heat detector inside the
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acoustic enclosure, which will be connected to the central fire alarm panel.
5.20 Necessary openings shall be made for the entry of power cable and control cables, fuel
piping, exhaust piping, air inlet pipe etc.
5.21 With the installation of the acoustic enclosure, there shall not be any de-rating of the DG
set. The maximum temperature of oil and water shall not exceed the limits prescribed by
the manufacturer of the engine. The DG set shall give rated output continuously.
5.22 The ventilation system shall be designed to provide an adeq uate air volume whenever the
DG set is in operation.
5.23 The ventilation fan shall be of the axial flow type designed to handle the static pressure
estimated based on the inlet air duct size and length.
6. Instrument / Control Panel
6.1 Instrument / Control Panel shall have the Equipment’s / Instruments but not limited to
the following
a) Auto Start / Stop control

b) Local / Remote / SCADA control
c) MCCB / ACB for power control
d) MCB for Control wiring
e) Lube oil pressure
f) Coolant temperature
g) Low Coolant Level
h) High Coolant Temperature
i) Over Speed
j) Engine start / stop key switch.
k) D.C Voltage.
l) Engine RPM
m) Operating Hours Meter
n) Over / Under Voltage
o) Over Current
p) Safety cutouts for low lube oil pressure high coolant temperature, over speed, emergency
stop, low coolant level and fail to start
q) Indications for the above safety cutouts
r) Alternator Voltage and Amperage of all 3 phases
s) Wiring harness using temperature resistant insulation and flexible copper conductor wires.
The wiring should be clamped at regular intervals and terminated using lugs.
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t) Stainless steel flexible for engine exhaust
u) Stop solenoid.
v) Panel illuminating lights
w) Emergency stop
x) DG set controller with RS 485 Communication / Equivalent port to communicate to
SCADA system (supplied by others) to control / monitor critical and essential system.
7. Accessories
7.1 The following accessories shall be supplied with the DG set
a) Common base frame for the Engine and Alternator

b) Anti-vibration mounts of reputed make in requisite quantity
c) Protective guards for all rotating parts
d) 18 G galvanized sheet steel trays beneath the engine, day tank and overflow collection tank
to collect the oil leakage
8. Batteries
8.1 The batteries shall be of heavy duty, high performance & rated for continuous duty.
8.2 Each battery shall be rated 24 V. The number and AH capacity shall be selected to suit
the engine requirements.
8.3 Battery shall be suitable for six successive starting attempts each of 10 seconds duration
with a gap of 5 seconds between successive starts.
8.4 The battery shall be supplied complete with electrolyte and accessories. The accessories
shall include battery stand, battery leads with terminal ends, acrylic top cover and inter
battery connectors. First charging of the batteries shall be included.
9. Control cabling
9.1 The cables shall comply with all currently applicable Indian Standards & IEC standards
and the following specific standards and codes:
9.2 Copper/Aluminium control cables - PVC / XLPE insulated, PVC sheathed 650/1100V
grade as per IS: 1554-I & IS: 7098 - I. Overall shielding if required with Aluminium
Mylar tape with 100% coverage & 25% overlap on laid up cores for static noise reduction.
9.3 Flexible, chord cables and wiring cables - PVC insulated & sheathed upto 1100V as per
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IS: 694, single and multi core.
9.4 Coaxial cables - RG and UR series as specified and as per MIL-C-17 / Bs: 2316 / IS 5068/
Is 11967 and suitable for 50/75/100/125 ohms
9.5 Signal cables as per BS:5308, DIN VDE 0815 & 816, IS: 1554, IEC: 189
9.6 Conductor shall be stranded / solid, circular / shaped - electrical grade aluminium / copper
as per IS: 8130 and IEC: 60228 / BS: 6360.
9.7 Cable Insulation as per IS: 5831 / IS: 7098 and BS: 6746 / BS: 5467 / IEC: 60502
9.8 Inner sheath & outer sheath shall be PVC / HR PVC / PVC FRLS / PVC FR as per ST 1
/ ST 2 / IEC 754 Part1 / IEC 60332 Part I & III / IEEE-383 / ASTM 2843 & 2863, EIL
Specs etc.
9.9 Armouring shall be G.S round wire / Flat strip or Aluminium wire / Flat strip over the
inner sheath as per IS 3975
10. Receipt of material at site
All material loading, unloading, transportation, (shifting and storage, safe keeping) etc., is under
the scope of DG vendor.
11. Testing, commissioning, training and approvals
Testing and commissioning shall be carried out based on the specifications, data sheets, BOQ and
the latest requirements of the various statutory authorities.
After installation as per the final approved drawing, the site testing shall be carried out by the
vendor as specified before commissioning the DG set system. After testing the entire system to the
satisfaction of the Executing Agency and their represents.
A thorough training of the operation and maintenance procedures etc as required or necessary shall
be given by the vendor to the Executing Agency’s representatives with appropriate write-ups and
manuals / catalogues as reference for a minimum period of three months after handing over.
The documents / drawings required for obtaining the approval / sanction from the Electrical
inspector, State Electricity board, State regulatory authority, Factory inspector, Pollution control
board, Regulatory authority, and any other statutory agency appointed for the purpose by the state
/ central / municipal / local bodies shall be prepared by the DG set supplier.
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12. Guarantee
The performance figures specified shall be guaranteed within the tolerance specified or as permitted
by relevant standards. In case of failure of equipment to meet the guaranteed performance, the
Executing Agency reserves the right to reject the equipment. However, the Executing Agency also
reserves the right to use the rejected equipment until new equipment meeting the guaranteed
performance requirements is supplied by the vendor at no extra cost. If any equipment supplied by
the vendor fails at site during erection, commissioning or service (within guarantee period), the
vendor shall repair and put back into successful operation the failed equipment within the time
frame and procedure of repair agreed with the Executing Agency depending on nature of failure at
no extra cost to the purchaser. The guarantee period shall be as specified in the commercial terms
and conditions.
13. Bar chart / Network
The Concessionaire to indicate following schedules:

 Manufacturing, Inspection & Testing at works
 Shipping
 Pre - commissioning / testing
 Commissioning
 Service kits with all filters and other consumables
 List of recommended spares for three years satisfactory operation.
14. Documentation and drawing requirements:
The following documents, drawings etc shall be submitted by the Concessioanire:
Data sheet / Compliance and guaranteed particulars statement.
DG layout plan showing all dimensions, including operational and maintenance clearances with
sections as required. The plan should also indicate ventilation requirement, civil foundations,
loading data, wall openings, etc. & generator earthing requirement
Schematic diagram of control panel with accessories like AVR, AMF, and auxiliary power
distribution details etc., along with cable schedule.
Terminal box drawing, literature, write-ups, description of DG set excitation system, voltage
regulator, governor, & other auxiliaries, catalogues / brochures etc.
Component list with rating & ranges of all items
Single line diagram for the whole system - control and power
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Technical specification sheet with brochures / catalogues and operational details for:
o DG sets
o Acoustic enclosure or Room sound proofing
o Detailed specification sheet for all auxiliary components giving material specifications,
make/model, capacity, ratings etc.
15. Testing
The following tests shall be carried out at the manufacturer’s works and the test results submitted
to the Executing Agency. The Executing Agency reserves the right to inspect the above tests or
waive the inspection.
 Tests on engine
o Engine starting time

o 4 hour running at full load followed by 1 hour running at 110 % of load
o Fuel consumption test:
o One hour running at 100% load
 Testing arrangement
o Arrangement for loading DG by: Vendor

o Fuel charges for site testing by: Vendor
 Shop tests
o All the tests required by the manufactures practice or by applicable standard during the
manufacture stage.
o Performance tests on the assembled diesel generator set. (With Voltage regulator)
o Check of fuel consumption at different loads.
o Measurement of Generator Winding Temperature after stabilized condition at 10 %
overload.
o Measurement of cooling water temperature of engine at 10% overload as above
o Measurement of vibration
o Measurement of sound level at 1 Meter Level and 10 Meter distance
o Functional tests on fuel transfer pump.
o Dielectric and insulation tests
o Routine test on voltage regulator
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o Hydrostatic Pressure test on both fuel tanks (at 2 Bars)
o Simulation of all protection
o Simulation of mains failure and mains return
o Load tests at 0.8 Power Factor
- 2 Hour at 100 % rated load
- 1 Hour at 110 % rated load
- 1 Hour at 75 % rated load.
- 1 Hour at 50 % rated load.
o Starting tests to show time of starting and load acceptance
16. Inspection, operation, maintenance Manuals
The supplier shall submit along with the delivery and/or on commissioning - as applicable, the
Type & Routine test certificates / Guarantee certificates, etc.
17. Make of DG set

The concessionaire to decide and get approval from the Executing Agency
18 Synchronization:
DG sets at any site will be designed to cater the peak demand of the site. Concessionaire may propose
more than one DG sets to share the total load with provision of synchronization between DGs which will
result in more reliability and fuel economy in case of part load requirements.
Synchronization panels are mainly designed and used to meet power system requirements.
These panels function both manually and with an automatic synchronizing function for two or more
generators or breakers. They are widely used in synchronizing generators and offering multiplex
solutions.
How does a synchronizing panel work?
Synchronizing panel will operate on an automatic mains failure system, so that when the main
supply is interrupted on one or all phases (after an adjustable delay period) the generator sets will start-up
together.
OPERATION PHILOSOPHY
Auto Mode
a) System Operation While the normal mains supply is healthy, the DG set shall be at rest and the
load shall be supplied by mains. During this period all the bus couplers shall be in OPEN
position. The controller system shall monitor supply voltage on each phase.
b) When the mains supply fails completely or falls below set value (variable between 80% to 95% of
the nominal value) on any phase, the monitor module shall initiate start up of diesel engine. To
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avoid initiation due to momentary dips or system disturbance, a time delay adjustable between 0.5
to 5 seconds (adjustable) shall be incorporated in the start up initiation.
c) A three attempt starting facility shall be provided with the sequence 6 seconds ON 5 seconds OFF
6 seconds ON 5 seconds OFF and 6 seconds ON. At the end of the third attempt if the engine has
not been already started and built up voltage, engine shall be locked out for start. A master timer
shall be provided for the function.
d) An audio visual alarm shall be given. Suitable adjustable timers shall be incorporated which shall
make it feasible to vary independently ON-OFF setting periods from 1-10 seconds. If the
alternator does not build up voltage after the first or any start, as may, further starting attempt
shall not be made and the starting facility shall be reset. Once engine has built up voltage, signals
shall be provided to operate the alternator, mains and bus coupler circuit breakers as per logic
sequence required.
e) The Mains supply circuit breaker shall open before the alternator circuit breaker closes. Before
giving close command to alternator breaker, all the bus couplers shall be given close command.
At this point of time all the load shall be on one DG. System provided in the DG Synchronization
control Panel shall check and ensure that all the engine auxiliaries like cub oil pump, CT fan,
cooling water pump are running and healthy. In case of any fault in engine auxiliaries, the system
shall automatically stop the DG set and an audio visual alarm shall be given. Suitable inputs for
overload and single phase preventor for alternator and for each of the engine auxiliaries shall also
be considered as inputs for this function.
f) DG Synchronization control system shall continuously monitor total load on the DG set. In case
the load on any of the DG sets is less than 60 % of the rated value, the controller shall assess the
load on the adjacent DG set. In case the summation of the loads is within 90% of the rating of one
of the DG sets, one DG set shall shut down and load shall be transferred to the second DG set. In
case the total load on the system is not more than 90% of the full load rating of a single DG set,
the controller shall shut down due to non availability of adequate load and will the load increase,
the controller shall automatically start the DG set and shall isolate the buses/loads on the Main LT
panel bus.
g) The Automatic Load Management system shall be designed to provide optimum utilization of the
DG sets so that operation of the DG sets is need based with higher load factor on each set. The
system would therefore transfer loads from one bus to the other on the Main LT panel with Main
L.T. panel as per logic sequence required.
h) The controller shall ensure that that the ACB’s on the closed and opened and DG sets are started
and stopped according to the predetermined logic and interlocking scheme to provide a fail safe
system. When the voltage in the mains get restored, its quality shall be monitored for about one
minute and if proven satisfactory, the main supply breaker shall close automatically for retransfer
of the load from Diesel engine to the main supply at LT panel. However prior to this operation
DG and bus coupler breakers shall open to ensure that all the bus couplers all the bus couplers are
in open position before the mains breaker closed.
i) The Automatic Logic Management system shall also consider that in the eventuality of failure of
any component of the controller, adequate safeguards shall be provided in that the system shall
revert to the manual mode with visual and audible alarms. These safeguards and the system shall
be detailed in the offer. The Logic Panel shall automatically arrange for sequential starting of DG
sets to be based on number of operating hours of each DG set so that to ensure that all DG sets
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are operated as equally as possible. In case of over load on the DG system, the logic panel shall
give audio visual alarm to enable the operators to switch off loads as required and if this is not
taken care of in predetermined time, the Logic Panel shall put the DG in shut down mode with
alarm. The DG set shall stop after idle running of one minute after restoration of main supply.
j) The DG set reverts to standby conditions and is ready to start will the mains supply fail again. b)
Sequence of operation for Auto start, Auto load management & Auto Synchronizing One failure
of grid supply, DG-1 shall start automatically and close its breaker shall start feeding the load. On
DG-1 attaining its full rated capacity, DG-2 shall start automatically. Voltage and frequency of
DG-2 shall be monitored and necessary commands shall adjust the parameters of DG-2 with bus.
System shall also monitor the slip frequency and the beat voltage of the machine or system.
k) The above sequence shall be followed for subsequent DG’s. It shall be possible to alter sequence
of DG set starting through manual selectors or through Man Machine Interface. Active Power
shall be made equal on both the machines automatically with the help of active load balancing
system through governor control. Reactive power shall be balanced automatically with the help of
quardature droop kit fitted on the machine. However, if quadrature droop system is not
functioning accurately, reactive load balancing system shall control AVR to achieve KVAR
regulation within present band with direct analog(+/-3,0-5,+/- 5 , etc. volt) control. Load
management system shall have 6 output contacts for tripping various loads by field wiring and
also trip the breaker of different DG set and give alarm for shutting off DG in accordance with
predefined parameters to avoid under loading / over loading / cascading effect of tripping and
unnecessary fuel wastage. On restoration of grid supply, DG breakers and Bus coupler breakers
shall be switched off in sequence with time delays to cover dips and grids supply breakers shall
be switched On.
l) Dg sets shall continue to run for one minutes after DG breaker has been switched OFF. It shall be
possible to alter crucial settings / time delays thru. Man Machine Interface. Controller,
annunciation system, protection system and metering system shall have compatibility for future
interface with PC for graphics displays / report generation. System shall have total manual
override.
m) Tenderers may note that the controller controls and sequence of operation are indicative of
requirements and the controller shall not withstanding the above, be complete in all respects to
achieve the control, monitoring and operation of DG sets indicated above.
Manual Mode
Under manual mode it shall be possible for the operator to start up the generator set by pressing
the (START) push button. Three attempt starting facility shall also be operative for the start up
function. Alternator, mains and bus coupler circuit breakers ‘CLOSE’ and ‘TRIP’ operations as
per logic sequence required shall be manual by pressing the appropriate push button on the panel.
Closure shall be feasible only after alternator has built up full voltage. If the load is already on
‘MAINS’ pressure on ‘CLOSE’ button shall be ineffective. When running under manual mode, if
the mains supply has failed, the load shall automatically get transferred to the alternator
immediately overriding the stipulation of pressure on ‘CLOSE’ button. Engine shut down, other
than due to faults shall be manual by pressing a ‘STOP’ button.
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Test Mode
When under ‘TEST’ mode pressure of ‘TEST’ button shall complete the start up sequence
simulation and start the engine. The simulation will be that of mains failure. Engine shall build up
voltage but the set shall not close alternator circuit breaker when the load is on the mains.
Monitoring performance for voltage/ frequency etc. will be feasible without supply to load. If
during TEST run the power supply has failed, the load shall automatically get transferred to
alternator. Bringing the mode selector to auto position shall shut down the sets.
19 DG sets will be fully compliant to CPCB/SPCB and other applicable guidelines regarding emmsions,
stack height etc.
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Section - G5.3
Erection, testing and commissioning
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Section G5.3: Erection, testing and commissioning
1. Equipment installation, testing and commissioning
1.1 Installation of equipment
a) In accordance with the specific installation instructions, specifications and best industry
practices and as approved and shown in the Concessionaire’s drawings or as directed by the
Executing Agency, the Concessionaire shall unload, erect, install, wire, test and place into
use of all electrical equipment included in the contract. Equipment shall be installed in a neat,
workmanlike manner so that it is level, plumb, square and properly aligned and oriented. If
material is supplied before installation site is ready, it needs to be stored as per applicable
codes / manufacturer’s recommendations / Executing Agency’s instruction in good
engineering manner including construction of storage yard, shed, rooms etc as per
requirement of the material.
b) The Concessionaire shall furnish all supervision, labour, tools, equipment, rigging materials
and incidental materials such as bolts, wedges, anchors, concrete inserts etc. required to
completely install, test and adjust the equipment.
c) Drawings, instructions and recommendations shall be correctly followed in handling,

settling, testing and commissioning of all equipment and care shall be exercised in handling
to avoid distortion to stationary structures, the marring of finish, or damaging of delicate
instruments or other electrical parts.
d) The Concessionaire shall erect and commission the equipment as per the instructions of the
Executing Agency and shall extend all co-operation to him.
e) In case of any doubt / query as to correct interpretation of drawings or instructions, necessary

clarification shall be obtained from the Executing Agency. The Concessionaire shall be held
responsible for any damage to the equipment consequent to not following instructions
correctly.
f) The Concessionaire shall move all equipment into the respective buildings through regular
doors or floors openings provided specifically for the equipment. The Concessionaire shall
make his own arrangement for lifting of equipment.
g) Where assemblies are supplied in more than one section, the Concessionaire shall make all
necessary mechanical and electrical connections between sections including the connections
between bus bars / wires. The Concessionaire shall also carry out the adjustments/alignments
necessary for proper operation of the circuit breakers. All insulators and bushings shall be
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protected against damage during installation. Insulators or business chipped, cracked or
damaged due to negligence or carelessness shall be replaced by the Concessionaire at his
own expenses.
h) The Concessionaire shall take utmost care in handling instruments, relays and other delicate
mechanisms. Wherever the instruments or relays are supplied separately, they shall be
mounted only after the associated control panels have been erected and aligned. The blocking
material/mechanism employed for the safe transit of the instruments and relays shall be
removed after ensuring that the panels have been completely installed and no further
movement of the same would be necessary. Any damage to relays and instruments shall be
immediately reported to the Executing Agency.
i) Care shall be taken during handling on insulating oil to prevent ingress of moisture or foreign
matter. In the testing, circulation, filtering, or otherwise handling of oil, rubber hose shall not
be used. Circulation and filtering of oil, the heating of oil by regulated short-circuit current
during drying runs and sampling and testing of oil shall be in accordance with the latest Code
of Practice IS:10028 (Part II) shall be carried out.
j) Inspection, storage, installation, testing and commissioning of transformers shall be in

accordance with the latest Indian Standard Code of Practice IS:10028. All commissioning
tests as applicable, vide Appendix B of IS:10028 (Part II) shall be carried out.
k) Switchgear, relay and control panels shall be installed in accordance with the latest Indian
Standard Code of Practice IS:10118. The switchgear panels shall be installed on finished
surface or concrete or steel sills. The Concessionaire shall be required to install and align any
channel sills which form part of the foundations. Tape or compound shall be applied where
called for. The base of outdoor type units shall be sealed in approved manner to prevent
ingress of moisture.
l) After installation of all power and control wiring, the Concessionaire shall perform operating
tests on all switchgear and panels to verify the proper operation of switchgear/panels and the
correctness of the interconnections between various items of equipment. This shall be done
by applying normal AC or DC voltage to the circuits and operating the equipment. Megger
tests for insulation, polarity installation tests shall be carried out by the Concessionaire who
shall also make all necessary for proper functioning of the equipment.
m) Installation and testing of the battery and battery chargers shall be done in strict compliance
with the applicable standards. Each cell shall be inspected for breakage and condition of
cover seals as soon as received at site. The battery shall be set up on racks as soon as possible
after receipt, utilizing lifting devices. The cells shall not be lifted by terminals. Contact
surface of the battery terminals and inter cell connectors shall be cleaned, coated with
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protective grease and assembled. Each connection shall be properly tightened. Each cell shall
be tested with an hydrometer and thermometer and the results logged. A freshening charge,
if required, shall be added. When handed over to the Executing Agency, the battery shall be
fully charged and the electrolyte shall be at the full level of the specified specific gravity.
n) Equipment furnished with finished coats of paint shall be touched up by the Concessionaire
if their surface is spoiled or marred while handling.
o) Foundation work and grouting-in of fixing bolts or channels for all transformer, switchgear,
motors and control panels will be carried out by the Concessionaire.
1.1.1 Installation work for earthing and lightning protection system.
o The Concessionaire shall install aluminium / copper / steel conductors/ Piped Earthing
Electrode, braids, etc. required for the system and individual equipment earthing. All work
such as cutting, bending, supporting, painting/coating, drilling, brazing/soldering/welding,
clamping, bolting and connecting onto structures, equipment frames, terminals, rails or other
devices shall be in the Concessionaire’s scope of work. All incidental hardware and
consumables such as fixing cleats/clamps, anchor fasteners, lugs, bolts, nuts, washing,
bituminous.
o The quantities, sizes, materials of earthing conductors and electrodes to be installed as per
requirement. Routes of the conductors and locations of electrodes shall be as shown on the
project drawings.
o The work of embedment of earthing conductor in RCC floors / walls along with provision of
earth plate inserts / pads / earth risers shall be done by the Concessionaire when the floors
are cast or during construction of walls. The Concessionaire’s scope of installation shall
include laying the conductors in position with 50 mm concrete cover, making welded
connections to inserts/pad/risers above the floor near the equipment. The embedded
conductors shall be connected to reinforcing rods wherever necessary.
o If the tap connections (earthing leads) from the floor embedded main earthing grid to the
equipment are more than 500 mm long then the same shall be embedded in floor by the
Concessionaire where required, together with associated civil work such as excavation /
chasing, concreting and surfacing, if not already done in the civil work. The concrete cover
over the conductor shall not be less than 50 mm.
o Installation of earth conductors in outdoor areas, buried in ground, shall include excavation
of earth upto 600 mm deep 450 mm wide, laying of conductors at 600 mm depth, brazing /
welding as required, of main grid conductor joints as well as risers of length 500 mm above
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ground at required locations and then backfiring material to be placed over buried conductor
shall be free from stones and other harmful mixtures. Backfill shall be placed in layers of 150
mm, uniformly spread along the ditch and tampered utilizing pneumatic tampers or other
approved means. If the excavated soil is found unsuitable for backfilling, the Concessionaire
shall arrange for suitable material from outside.
o Installation of earth connection leads to equipment and risers on steel structures / walls shall
include laying the conductors, welding / cleating at specified intervals, welding / brazing to
the main earth grid risers, bolting at equipment terminals and coating welded / brazed joints
by bitumen paint. Galvanized conductors shall be touched up with zinc rich paint where holes
are drilled at site for bolting to equipment / structure.
o Electrodes shall be installed (a) directly in earth, or (b) in constructed earth pits and connected
to main buried earth grid. The scope of work shall include excavation, construction of the
earth pits including all materials required for construction of earth pits, placing the rod and
fixing test links on those pipe / rod / plate electrodes in test pits and connecting to main earth
conductors.
o Installation of lightning conductors on the roofs of buildings shall include laying, anchoring,
fastening and cleating of horizontal conductors, grouting of vertical rods wherever necessary,
laying fastening / cleating / welding of the down comers on the walls / columns of the
building and connection to the test links to be provided above ground level.
o Installation of the test links shall include mounting of the same at specified height on wall /
column by suitable brackets and connections of the test link to the earth electrode.
o Whenever main earthing conductor crosses cable trenches, they shall be buried below the
trench floor.
o Suitable earth risers shall be provided above finished floor/ground level. If the equipment is
not available at the time of laying of the main earth conductors, the minimum length of such
riser inside the building shall be 200 mm and outdoors shall be 500 mm above ground level.
The risers to be provided will be marked in project drawings.
o Earth leads and risers between equipment earthing terminal and the earthing grid shall follow
as direct and short a path as possible.
o Wherever earthing conductors passes through walls galvanized iron sleeves shall be provided
for the passage of earthing conductor. The pipe ends shall be sealed by the Concessionaire
by suitable water proof compound.
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1.1.2 Earthing connections
o All connections in the main earth conductors buried in earth/concrete and connection
between main earthing conductor and earth leads shall be of welded type.
o Connection between earth leads and earthing terminal provided on the equipment shall be
bolted type.
o All bimetallic connections shall be treated with suitable compound to prevent moisture
ingression.
o Metallic conduits and pipes shall be connected to the earthing system.
o Lightning protection system down conductors shall not be connected to other earthing
conductors above ground level. Also no intermediate earthing connection shall be made to
lightning arrestor and transformer earthing leads which shall be directly connected to plate
electrode.
1.1.3 Earth electrodes
o Electrodes shall as far practicable, be embedded below permanent moisture level.

o Test pits with concrete covers shall be provided for periodic testing of earth resistance.
Installation of plate electrodes in test pits shall be suitable for watering. The necessary
materials required for installation work shall also include civil work such as excavation and
connection to main earth grid.
o Earth pits shall be treated with salt and charcoal.
o Soil, salt and charcoal placed around the electrode shall be finely graded, free from stones
and other harmful mixtures. Backfill shall be placed in layers of 250 mm thick uniformly
spread and compacted. If excavated soil is found unsuitable for backfilling, the
Concessionaire shall arrange for a suitable soil from outside.
1.1.4 Lightning protection system
o The lightning protection of air termination rods and/or horizontal air termination conductors
shall be fixed in such a way that they remain in their installed position even during severe
weather conditions. The necessary accessories such as cleats, clamps, welding materials,
bolts, nuts shall be supplied by the Concessionaire.
o Air termination system shall be connected to earthing system by down conductors. The down
conductors shall follow a direct path to earth. There shall not be any sharp bends, turns and
kinks in the down conductors.
o All joints in the down conductors shall be of welded type. All metallic structures within 2
metres of down conductors shall be bonded to lightening protection system.
o Every down conductor shall be provided with a ‘test link’ at about 1000 mm above ground
level housed in a suitable G.I. enclosure made of adequate thickness steel sheet and hot-dip
galvanised. The test joint shall be directly connected to the earthing system electrode.
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o The lightning protection system shall not be in direct contact with underground metallic
service ducts, cables, cable conduits and metal enclosures of electrical equipment. However,
all metal projections, railings, vents, tanks, etc. above the roof shall be bonded together to
form a part of roof grid.
1.2 Installation of cable racks and trays
a) Lines and grade for trays may be measured from building steel and finished floor elevations.
Changes in line or grade, or the addition of offsets by means of cutting standard tray sections
and inserting additional tray fittings to match with the existing arrangement shall be
considered as a normal part of the work.
b) Where embedded steel inserts in concrete floors/walls for welding the supports for cable
racks/trays are not available, Concessionaire shall provide suitable anchor fasteners at no
extra cost.
c) Cable shall be clamped to the cable trays at regular intervals.
d) Flexible metallic conduits shall be used for termination of connection to equipment such as
motors, limit switches and other apparatus.
1.3 Installation of cables
a) The Concessionaire shall install, test and commission the cables specified in the
specification in accordance with drawings & instructions issued by the Executing
Agency representative. Cables shall be laid directly buried in earth, on cable racks, in
built-up trenches, on cable trays and supports, in conduits and ducts or bare on walls,
ceiling etc. as per drawings. Concessionaire’s scope of work includes unloading, laying,
fixing, jointing, bending and termination of the cables. The Concessionaire shall also
supply the necessary materials and equipment required for jointing and termination of the
cables.
b) All apparatus, connections and cable work shall be designed and arranged to minimise
risk of fire and any damage which might be caused in the event of fire. Wherever cables
pass through floor or wall openings or other partitions, suitable bushes of an approved
type shall be supplied and put into position by the Concessionaire.
c) Standard cable grips and reels shall be utilised for cable pulling. If unduly difficult pulling
occurs, the Concessionaire shall check the pull required and suspend pulling until further
procedure has been approved by the Executing Agency. The maximum pull tension shall
not exceed the recommended value for the cable measured by the tension dynamometer.
In general, any lubricant that does not injure the overall covering and does not set up
undesirable conditions of electrostatic stress or electrostatic charge may be used to assist
in the pulling of insulated cables in conduits and ducts.
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d) After pulling the cable, the Concessionaire shall record cable identification with date
pulled neatly with waterproof ink in linen tags. Identification tags shall be attached
securely to each end of cable with non-corrosive wire. The said wire must be non-ferrous
material on single conductor power cable. Tags shall further be attached at intervals on
long runs of cables on cable trays and in pull boxes. Cables and joint markers and RCC
warning covers shall be provided wherever required. All cables shall be allocated a unique
number which shall be fixed to each end of the cable using corrosion resistant label. Cable
of different categories shall be tagged with the following subscripts and three digit
number.
- HV power HV-P _____

- LV power P _____
- Control C _____
- Instrumentation I ______
- Protection PR_____
- Telecommunication T_______
e) Sharp bending and kinking of cables shall be avoided. The bending radii for various types
of cables shall not be less than those specified below :
- KV XLPE multicore armoured cables: 15 times the overall dia of the cable
- 650 / 1100 V PVC insulated armoured cables: 12 times the overall dia of the cable
If shorter radius appears necessary, no bend shall be made until clearance and instructions
have been received from the Executing Agency.
f) Power, control and instrumentation cables shall be laid in separate cable racks / rays.
g) Where groups of HV, LV and control cables are to be laid along the same route, suitable
barriers to segregate them physically shall be provided.
h) Cables of different categories shall be installed so as to maintain satisfactory clearances

for safety and in order to reduce the possibility of electrical interference. The following
table gives the distances in mm that shall be maintained between the different categories
/ voltage grade of cable.
Cable category HV LV C&I Telecommunication /

Power Power Protection data network
HV Power - 275 550 550
LV Power 275 - 275 275
C&I Protection 550 275 - 275
Telecommunication 550 275 275 -
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i) Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in
reinforced spun concrete or steel pipes. For road crossings the pipe for the cables shall be
buried at not less than one metre depth.
j) Cables laid in ground shall be laid on a 50 mm riddled earth bed. The cables shall then be
covered on top and at their sides with riddled earth of depth of about 150 mm. This is then
gently filled up to a depth of about 100 mm above the top of uppermost cable to provide
bedding for the protective cable covers which are placed centrally over the cables. The
protective cable covers for LV cables may be of earthenware and for HV cables of
reinforced concrete. The RCC covers shall have one hole at each end, to tie them to each
other with GI wires to prevent displacement. The trench is then backfilled with the
excavated soil and well rammed in successive layer of not more than 300 mm depth, with
the trenches being watered to improve consolidation wherever necessary. To allow for
subsidence, it is advisable to allow a crown of earth not less than 50 mm in the centre and
tapering towards the sides of the trench.
k) In each cable run some extra length shall be kept at a suitable point to enable one or two
straight through joints to be made, should the cable develop a fault at a latter date.
l) Cables on cable racks, on cable trays and conduits shall be formed to avoid bearing against
edges of trays, racks, conduits or their supports upon entering or leaving trays, racks or
conduits. Cables shall be racked or laid directly into cantilevered cable trays where
practicable, but in some cases it may be necessary that cables are pulled or threaded into
trays. To facilitate visual tracing, cables in tray shall be laid only in single layers and
unnecessary crossing of cables shall be avoided. Cables on trays shall finally be clamped
in an approved manner.
m) Cable splices will not be permitted except where permitted by the Executing Agency.
Splices shall be made by Concessionaire for each type of wire or cable in accordance with
the instructions issued by cable manufacturer’s and the Executing Agency. Before
splicing, insulated cables shall have conductor insulation stepped and bound or pencilled
for recommended distance back from splices to provide a long leakage path. After
splicing, insulation equal to that on the spliced conductors shall be applied at each splice.
n) Jointing of cables shall be in accordance with relevant Indian Standard Code of Practice.
Materials and tools required for cable jointing work, including cold setting bituminous
compound shall be supplied by the Concessionaire. Cables shall be firmly clamped on
either side of a straight through joint at a distance of not more than 300 mm away from
the joints. Identification tags shall be provided at each joint at all cable terminations.
o) At cable terminal points where the conductor and cable insulation will be terminated,
termination shall be made in neat, workmanlike and approved manner by men specialised
in this class of work.
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p) Control cable termination shall be made in accordance with wiring diagrams, using colour
codes established by the Executing Agency for the various control circuit, by code marked
wiring diagram.
q) When control cables are to be fanned out and cabled together with cord, the
Concessionaire shall make connections to terminal blocks, and test the equipment for
proper operation before cables are corded together. If there is any question as to the proper
connection, the Concessionaire shall make a temporary connection with sufficient length
of cables so that the cable can be switched to another terminal without splicing. After
correct connections are established through operating the equipment, cables shall be cut
to their correct lengths, connected to terminals in the specified manner, and corded
together where necessary to hold them in place in a workmanlike manner.
r) Cable seals shall be examined to ascertain if they are intact and that cable ends are not
damaged. If the seals are found to be broken the cable ends shall not be jointed until after
due examination and testing by the Executing Agency. Before jointing is commenced,
insulation resistance of both sections of cables to be jointed shall be checked by megger.
s) After installation and alignment of motors, the Concessionaire shall complete the conduit
installation, including a section of flexible conduit between motor terminal box and
trench/tray. The Concessionaire shall install and connect the power, control and heater
supply cables as per equipment manufacturer’s drawings, if any.
t) For directly buried underground cables, Concessionaire shall install galvanised cast iron
cable markers over ground, at all bends, loops, joints, crossing points and at every 25
meters interval on straight runs. The cable markers shall be anchored in the ground to a
depth of minimum 500 mm. The cable markers for L.T. cables & HT cables shall be
distinctly different in shape and marked as L.T. Cables and HT Cables as the case may
be by 30 mm size letters.
1.4 Lighting system installation
This covers the requirements of installation of the following :-
a) Lighting fixtures complete with lamps and accessories

b) Main Lighting distribution board
c) Lighting panels
d) Receptacles and lighting control switches
e) Point wiring
f) Street lighting poles and flood light towers
g) Multicore cables for street and boundary lighting
h) Maintaining equipment/materials during storage and being responsible for the
equipment/material until they are handed over to the Executing Agency.
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i) Installation, testing and commissioning shall be carried out in accordance with the
drawings and as stipulated in this specification.
1.4.1 Applicable standards
Electrical wiring installations : IS:732

(system voltage exceeding 650 V)
Code of practice for interior illumination (Part-1) : IS:3646/BS:8206
Code of practice for street lighting installation : IS:1944
Code of practice for industrial lighting : IS:6666
Code of practice for fire safety of building : IS:1646
Boxes for enclosure of electrical accessories : IS:5133 (Part I)
Guide for safety procedures and practices in : IS:5216

electrical work
Ceiling roses : IS:371
1.4.2 Lighting fixtures
a) The installation of lighting fixtures shall be based on the mounting arrangement shown in the
drawings enclosed. Installation shall include all materials required to mount the fixtures in
the manner as shown in the drawings. Installation of lighting fixtures shall include installation
of control gear box wherever applicable.
b) Installation of receptacles and switches shall be carried out suitably as per the lighting layout
drawings prepared by Concessionaire and approved by Executing Agency. Switch shall be
mounted in flush with the front cover plate. Supply and installation of necessary hardware
shall be included in the scope for installation of receptacles/switches.
c) Lighting distribution boards shall be installed at the location indicated in the layout drawings
prepared by Concessionaire and approved by Executing Agency. Installation rates quoted for
installation of lighting distribution boards shall include supply and installation of base
channels, foundation bolts, etc.
d) Outdoor lighting distribution boards shall be installed on a concrete plinth. The top of plinth
shall be 100 mm (min.) above the ground level. Construction of concrete plinth shall be
included in the installation of outdoor lighting distribution board. Installation cost of lighting
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distribution board shall include installation of earthing conductor from LDB to the nearest
earthing grid.
1.4.3 Point wiring
 Supply and installation of conduit point wiring
 The point wiring shall include supply of necessary materials for the conduit wiring such as
galvanised rigid steel conduit, galvanised M.S. fixing saddles with spacer plates, nylon/fibre
plugs, galvanised M.S. fixing screws, 12 SWG galvanised steel earthing wire, PVC insulated
copper or aluminium conductor wires, control switches and pulling, termination of the
earthing/PVC insulated wires as required, installation of control switches, drilling holes in brick
walls/RCC roof slabs for taking the wiring conduits and refinishing any other works/material
necessary for making point wiring complete in all respects.
 Wires used for conduit point wiring of lighting fixtures/ceiling fans and receptacles shall be
1100 V grade, PVC insulated, single core, stranded copper conductor wires of sizes not less
than 1.5 sq.mm and 2.5 sq.mm respectively. Wires shall conform to IS:694 and shall bear the
ISI mark.
 Concessionaire shall take into consideration necessary galvanised MS fixing clamps when the
wiring conduits are to be supported from steel roof truss/structural members.
 Point wiring shall also include/hold good for the following:
 Supply and installation of lighting control switches and switchboxes complete with fixing
accessories.
 Drilling holes in brick/RCC wall & roof for taking cable or conduit, sealing and refinishing
with cement plaster.
 Testing, commissioning and handing over the lighting system in commercial working
condition.
 Outdoor Lighting (Street and Flood Lighting)
The following shall be deemed to be included as part of the installation work for outdoor lighting
point wiring.
 Installation of multicore/single core cables between LDB and junction box mounted on street
light pole/flood lighting tower, from junction box to metal enclosed control gear box.
527
 Supply and installation of crimping type cable lugs, double compression type cable glands at
each junction box and fixture, termination and testing and commissioning of cables.
 Concessionaire’s scope shall also include excavation and preparation for buried cables. Supply
and installation of route markers, supply and installation of HDPE pipes for road crossing shall
also be included.
 Supply and installation of necessary cleating arrangement for cabling on flood light poles.
 Concessionaire shall provide necessary foundation for erecting street light pole/flood light
tower and install the same. Concessionaire shall prepare foundation drawings with necessary
details to Executing Agency for approval.
 Concessionaire shall plan and cut the cables in such a way that there is no wastage and no cable
jointing is required in any run. However, should any joint become necessary, the same shall be
provided by the Concessionaire and joint marker shall also be provided at no extra cost.
 Earthing of street light pole/flood light tower, lighting fixtures, control gear boxes, junction
boxes, etc. are also included in the scope of installation. Concessionaire shall earth street light
pole/flood light poles and junction box with 25 x 3 mm G.S. flat tap off from the 25 x 3 mm
M.S. flat earthing grid along the street lighting included in the scope. The Concessionaire shall
interconnect earthing grid to plant main earthing grid at first and last pole of each feeder circuit
and at one intermediate pole.
 Installation of lighting poles & towers for outdoor lighting (Street and flood lighting)
 Work includes supply and installation of street light poles and flood light towers including
associated junction boxes with fuses, links and terminals for junction boxes and junction boxes
near each flood light fixtures.
 All street light poles and towers shall be painted with two coats of red oxide oil primer followed
by two coats of aluminium alkyd paint.
 Installation of Lighting Distribution Board, Lighting Panels (AC & DC), 240 V, AC 1-Phase
Distribution Boards
Installation of above items shall include necessary foundation channels, bolts/nuts, etc. for grouting
lighting distribution boards, iron brackets/grouting brackets, bolts/nuts for wall/column mounted
panels and associated civil works.
528
1.5 Point wiring
1.5.1 Wiring
a) Wiring shall be carried out strictly as per project drawings and technical specification. All
exposed conduit wiring shall have provision for easy inspection. Exposed wiring when run
along wall shall be as near the ceiling as possible. Where cable wiring is specified cable shall
be cleated on to the wall as close to the ceiling as possible. In all types of wiring due
consideration shall be given for neatness and appearance.
b) Wherever DC emergency lighting is provided, emergency lighting wires shall run in a

separate conduit. Colour of the wires used shall be as follows; white for positive, black for
negative.
c) Wherever lighting system has three phase distribution, separate conduits shall be used for
different phases. For easy identification of phases and neutral wires, the following colour
wires shall be used.
(i) R - Phase - Red

(ii) Y - Phase - Yellow
(iii) B - Phase - Blue
(iv) Neutral - Black
d) There shall be a circuit breaker or a linked switch on each live conductor of supply mains at
the point of entry. The wiring throughout the installation shall be such that there is no break
in neutral wire in the form of switch or fuse unit.
e) Conductors not arranged for connection to the same system or supply different phases of the
same supply, shall be kept apart throughout their entire run.
f) Receptacles and lighting fittings in general shall be fed from different circuits. Five amps
receptacles for toilet or small rooms can be fed from the lighting circuit with proper isolating
arrangement.
g) Each final sub-circuit from a lighting panel shall be controlled by a single pole switch
connected to the live conductor.
h) For long conduit wiring runs, inspection/pull boxes shall be provided at intervals not
exceeding 10 m. Such facilities shall also be provided at conduit bends.
529
1.5.2 General practices
a) All receptacles and switches to be installed in offices and control rooms shall be flush
mounted within the wall and those in other areas shall be wall or column mounted.
b) Ceiling roses shall not embody fuse terminals as an integral part. For voltages exceeding 250
volts, a ceiling rose or any similar attachment shall not be used.
c) A socket outlet shall not embody fuse terminals as an integral part of it. The switch
controlling the socket outlet shall be on the live side of the line.
d) All exposed metal parts of the plug, when the plug is in complete engagement with the socket
outlet, shall be in effective electrical connection with the earthing pin.
1.5.3 Earthing
a) Exposed conduits and fittings shall be earthed by 12 SWG GI wires run along the length of
the conduit and secured by means of suitable clamps efficiently fastened to conduit tip. To
achieve perfect electrical continuity, the conduits shall be bonded effectively on either end
of a coupling and other joints. In case of concealed wiring 1.5 / 2.5 sq.mm PVC insulated
copper wire inside the conduit shall be used for earthing.
b) Conduits shall be earthed at the ends adjacent to switch boards at which they originate or
otherwise at the earth clip, clamp or gland, in effective electrical contact with the conduit.
c) For outdoor lighting poles the earthing conductor shall be terminated upto the junction box
on the pole and 12 SWG wire shall be taken up to the pole fitting.
1.6 Pre-Commissioning checks and commissioning
All checks and tests shall be as per the Manufacturer’s drawing manuals, relevant codes of
installation and commissioning check lists as given below :-
a) Among other commissioning tests, the following shall be carried out at site after completion
of installation. Concessionaire shall ensure to use calibrated test equipment having valid
calibration test certificates from standard laboratories traceable to National Standards /
International Standards. All tests to be carried out in the presence of Executing Agency.
(i) For Transformers
Dielectric strength of transformer oil. Operation of all protective equipment,

voltage/turns ratio at all taps, winding resistance at all taps, vector group test, phase
sequence test, buchholz relay operation (alarm and trip), OLTC control indicating and
alarm circuits, lightning arrestor installation, test the bushing oil for dielectric strength.
530
(ii) For Switchgear
Power frequency high voltage test, operation tests.
(iii) For Relays
Check internal wiring, relay settings.
Satisfactory operation over their whole operating range by secondary injection. Check
the minimum pick up voltage of D.C. coils, megger all terminals to body and AC to
DC terminals.
(iv) Relay and Control Panel
Switch development, check on relays, check on metres, functional checking of all

control circuit, e.g. closing, tripping, control, interlock, supervision, and alarm circuits
including proper functioning of the component equipment.
(v) Circuit breakers
Manual operation of breakers, power closing/opening operation manually and

electrically, breaker closing and tripping time, trip free and anti pumping operation,
control wiring for correctness of connections, continuity and IR value, electrical and
mechanical interlocks, all functional checks on CTS, checks on spring charging motor.
(vi) Battery
Special gravity test, cell voltage check, capacity test as per IS, Initial charging cycle.
(vii) Battery charger & D.C. Distribution Board
Functional check of auxiliary devices such as alarms, indicating etc., measurement of

voltage regulation.
(viii) Voltage transformers
Polarity test, ratio test on all cores, oil level and leakages, ‘Insulation resistance test’,
earthing connection.
(ix) Current Transformer
Megger between windings and winding terminal to body, polarity test, capacitance and
tan delta test.
531
(x) Cables
 All new cables shall be tested for its insulation strength before terminating / jointing.
After terminating / jointing is completed of all L.V. (i.e. 650/1100V) cable shall be
tested by 1000V megger. All H.T. Cables (i.e. 11 KV) shall be tested by 2500 V
motor operated megger.
 Cable core shall be tested for
- Continuity
- Absence of cross phasing
- Insulation resistance to earth
- Insulation resistance between conductors
(xi) Earthing and Lightning Protection System
The Concessionaire shall ensure the continuity of all conductors and joints. The
Executing Agency may ask for earth continuity tests earth resistance measurements
and other tests which in his opinion are necessary to prove that the system is in
accordance with design, specification, code of practice and electricity rules. Earth
resistance value should be not greater than one (1) ohm,
(xii) Lighting System
Before putting complete system into service, commissioning tests stipulated in

applicable standards and code of practice shall be carried out by the Concessionaire in
the presence of the Executing Agency covering all lighting system equipment.
(xiii) The Concessionaire shall carry out insulation resistance tests by megger of
following rating:
 Control circuits upto 220 V : 500 V megger

 Power circuits upto 1.1 KV : 1000 V megger
1.7 Safety procedure and practice
Following safety procedure and practice should be provided by concessionaire in switchgear

room/sub-station as per latest edition of I.S. 5216.
a) Rubber matting
(i) In front of 33/11 KV switchgear.
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(ii) In front of 6.6/3.3/0.415 KV switchgear and other panel in switchgear room.
b) Shock treatment charts
(i) One chart near 33/11 KV switchgear room

(ii) One chart near 6.6/3.3/0.415 KV switchgear room
c) Caution/Danger Board
(i) 33/11 KV switchgear

(ii) 11 KV capacitor panel
(iii) 6.6/3.3/0.415 KV switchgear
(iv) Transformer near H.T. cable box
(v) All power Distribution Board
d) Fire Safety
The requirement of hand appliance in switchgear room, electrical equipment room shall be
provided as per Clause 4.0 of Fire Protection Manual by Regional Traffic Committee, 10th
edition 1988.
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Section - G5.4
Instrumentation Works
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Section G5.4: Instrumentation Works
1. General
The Concessionaire is required to adopt the latest technology with compatible automation
system having fully automatic process control, The “Plant Control Configuration” to be provided
by the Concessionaire as part of Basic engineering package. ON LINE to monitor and control the
plant from a single location. The data collected through online monitoring shall be made available
via the internet to authorities & officials in Executing Agency, the NMCG, CPCB, SPCB, ULB
and Project Engineer.
2. General requirements
This part covers the general requirements for the design, supply, installation, inspection and testing
of the instrumentation and automation solution proposed for flow measurement, monitoring of
water quality and control of plant.
3. Reference Standards
Unless otherwise approved, instrumentation shall comply with relevant quality standards test
procedures and codes of practice collectively referred to as Reference Standards including those
listed below in accordance with the requirements detailed elsewhere in this specification. IEC
60381-1:1982 Analogue signals for process control systems.
ISA Water/Wastewater and Automatic Controls (WWAC) Proceedings in 2016 can be referred
for advances in instrumentation, SCADA (supervisory control and data acquisition), and
automatic control applications can improve the treatment and distribution of water, as well as the
collection and treatment of wastewater. Other topics covered include:
 Cybersecurity
 Wireless communications
 DNP 3.0 protocol
 Smart water
 Alarm management
 Optimizing process controls
o IEC 60947-4-1:2000 Specification for low-voltage switchgear and Control Gear. Contactors
and motor-starters. Electromechanical contactors and motor-starters.
o IS 15953 : 2011
o ISA-5.1-2009
o IEC 62443
o IEC 61346
o IEC 60870-6- all parts
o IEC 61131-3 industrial control programming standard advancements
535
o IEC 61850 all parts ranging from 1 - 10
o IEC 61850-10:2012 - Conformance testing 118
o IEC TR 61850-90-3:2016 - Using IEC 61850 for condition monitoring diagnosis and analysis
+ IEC TR 61850-90 all parts
and motor-starters. A.C. semiconductor motor controllers and starters.
and motor-starters. Contactors and motor-starters. AC semiconductor controllers and
contactors for non-motor loads.
o IEC 60770-1:1999 Transmitters for use in industrial-process control systems. Methods for
performance evaluation.
o BS ISO 1217:1996 Displacement compressors. Acceptance tests.
o ISO 2112:1990 Specification for aminoplastic moulding materials.
o ISO 6817:1997 Measurement of conductive liquid flow in closed conduits. Method using
electromagnetic flow meters.
o BS EN 837-1:1998 Pressure gauges. Bourdon tube pressure gauges. Dimensions, metrology,
requirements and testing.
o BS EN 1057:1996 Copper and copper alloys. Seamless, round copper tubes for water and gas
in sanitary and heating applications.
o BS EN 1092-1:2002 Flanges and their joints. Circular flanges for pipes, valves, fittings and
accessories, PN designated. Steel flanges.
o BS EN 1563:1997 Founding. Spheroidal graphite cast iron.
o BS EN 60529:1992 Specification for degrees of protection provided by enclosures (IP code).
o BS EN 60534-1:1993 Industrial-process control valves. Industrial-process control valves.
Control valve terminology and general considerations.
o BS EN 60546-1:1993 Controllers with analogue signals for use in industrial-process control
systems. Controllers with analogue signals for use in industrial-process control systems.
o BS EN 60584-2:1993 Thermocouples.
o BS EN 60654:1998 Operating conditions for industrial-process measurement and control

equipment. All relevant parts.
o BS EN 60751:1996 Industrial platinum resistance thermometer sensors.
o BS EN 60873:1993 Methods of evaluating the performance of electrical and pneumatic
analogue chart recorders for use in industrial-process control systems.
o BS EN 61000-6:2001 Electromagnetic compatibility (EMC). Generic standards. Emission
standard for industrial environments.
o BS 89:1990 Direct acting indicating analogue electrical measuring instruments and their
accessories. All parts.
536
o BS 90:1975 Specification for direct-acting electrical recording instruments and their
accessories.
o BS 476 Fire tests on building materials and structures. All parts.
o BS 1042-1.4:1992 Measurement of fluid flow in closed conduits. Pressure differential devices.
Guide to the use of devices specified in Sections 1.1 and 1.2.
o BS 1041-2.1:1985 Code for temperature measurement. Expansion thermometers. Guide to
selection and use of liquid-in-glass thermometers.
o BS 1041-2.2:1989 Code for temperature measurement. Expansion thermometers. Guide to 119
selection and use of dial-type expansion thermometers.
o BS 1041-3:1989 Temperature measurement. Guide to selection and use of industrial resistance
thermometers.
o BS 1041-4:1992 Temperature measurement. Guide to the selection and use of thermocouples
o BS 1042-1.4:1992 Measurement of fluid flow in closed conduits. Pressure differential devices.
Guide to the use of devices specified in Sections 1.1 and 1.2.
o BS 1123-1:1987 Safety valves, gauges and fusible plugs for compressed air or inert gas
installations. Code of practice for installation.
o BS 1203:2001 Hot-setting phenolic and aminoplastic wood adhesives. Classification and test
method.
o BS 1553-1:1977 Specification for graphical symbols for general engineering. Piping systems
and plant.
o BS 1571-2:1975 Specification for testing of positive displacement compressors and exhausters.
Methods for simplified acceptance testing for air compressors and exhausters.
o BS 1646-1:1979 Symbolic representation for process measurement control functions and
instrumentation.
instrumentation. Specification for additional basic requirements.
instrumentation. Specification for detailed symbols for instrument interconnection diagrams.
instrumentation. Specification for basic symbols for process computer, interface and shared
display/control functions.
o BS 1794:1952 Specification for chart ranges for temperature recording instruments.
o BS 2765:1969 Specification for dimensions of temperature detecting elements and
corresponding pockets.
o BS 3680 Measurement of liquid flow in open channels. All relevant parts.
o BS 3693:1992 Recommendations for design of scales and indexes on analogue indicating
instruments.
o BS 4675-2:1978 Mechanical vibration in rotating machinery. Requirements for instruments for
measuring vibration severity.
o BS 4999-142:1987 General requirements for rotating electrical machines. Specification for
mechanical performance: vibration.
537
o BS 5169:1992 Specification for fusion welded steel air receivers.
o BS 5728-3:1997 Measurement of flow of cold potable water in closed conduits. Methods for
determining principal characteristics of single mechanical water meters (including test
equipment).
o BS 6004:2000 Electric cables. PVC insulated, non-armoured cables for voltages up to and
including 450/750 V, for electric power, lighting and internal wiring.
o BS 6739:1986 Code of practice for instrumentation in process control systems: installation
design and practice.
o BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations. Sixteenth
edition. Instrument Society of American Standards and Recommended Practices:
o S 5.1 Instrumentation symbols and identification
o S 5.4 Instrument loop diagrams
o S 7.3 Quality standard for instrument air
o RP 16.1 Terminology, dimensions and safety practices for indicating variable 2, 3 area meters
o RP 16.4 Nomenclature and terminology for extension-type variable-area meters (rotameters)
o RP 16.5 Installation, operation, maintenance instructions for glass tube variable area meters
(rotameters)
o RP 16.6 Methods and equipment for calibration of variable area meters (rotameters)
o RP 18.1 Specifications and guides for the use of general purpose enunciators
o S 26 Dynamic response testing of process control instrumentation
o RP 31.1 Specification, installation and calibration of turbine flow meters
o S 37.1 Electrical transducer nomenclature and terminology
o S 37.3 Specifications and tests for strain gauge pressure transducers
o S 50.1 Compatibility of analog signals for electronic industrial process instruments
o S 51.1 Process instrumentation terminology
o RP 60.08 Electrical Guide for Control Centers
Installation works shall comply with all relevant local Indian Regulations including the Code
of Practice for Electrical Wiring Installations – IS 732.
4. Basic Features
Each instrumentation system shall be designed, manufactured and installed to achieve the following
basic requirements:
o To maintain the highest standards of availability, reliability and accuracy and to give clear
warnings of any deterioration in performance
o To suit the abilities of the staff who will:
(i) Use the systems
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(ii) Service the systems
o To measure, indicate, process, store and control the relevant parameters, as specified
o To give clear warnings of dangerous and other abnormal conditions and to initiate plant safety
procedures, shutdowns and corrective measures as specified to assure the safety of ‘operations
and maintenance’ personnel and that of the plant and to store and collate the data, as required
o To derive, present and utilize, as required, such additional data to facilitate:
(i) The most efficient operation of the plant
(ii) The routine maintenance of the plant
5. Design requirements for instrumentation and control systems (I&C)
The instrumentation, control and automation installations shall fully comply with design standards,
regulations and the material and workmanship requirements of the Specification. The
instrumentation control and automation systems shall comply with the relevant Indian Standards
being practiced as per the industry norms. All consumable items and spare parts shall be readily
available within India.
All equipment and materials incorporated in the system shall be selected, designed and rated to
operate under the defined performance duties and specified site conditions and to maintain a high
level of operational reliability. The instrumentation control and monitoring system equipment and
materials shall have an operational life of not less than 15 years.
Unless otherwise specified, all functions shall be transmitted electrically and all analogue signal
transmission systems shall be in accordance with IEC 60381-1:1982 or equivalent and shall use a
signal of 4mA to 20mA dc. Where possible, measuring systems shall be designed so that any
necessary power supply is taken from the appropriate instrument panel. Transmitting devices shall
have integral indicators to monitor the output signal or connections suitable for use with a portable
test meter, and shall be capable of meeting the requirements specified in the appropriate part of IEC
60770-1:1999 or equivalent. Equipment mounted in enclosures shall be suitable for continuous
operation at the maximum internal temperature possible in service, due account being taken of
internally-generated heat and heat dissipated by other plant. All components shall be rated
adequately and circuits shall be designed so that change of component characteristics within the
manufacturers’ tolerances shall not affect the performance of plant. All equipment shall be designed
to operate without forced (or fan) cooling.
All measuring instruments shall have zero and span adjustment. Instruments not mounted in panels
shall be supplied complete with all brackets, stands, supporting steelwork and weatherproof
enclosures (separate from the instrument cases) necessary for securing them in their working
positions and affording complete protection at all times including periods of servicing, adjustment,
calibration and maintenance. The installation arrangements for meters measuring conductivity, pH,
dissolved oxygen, chlorine residual and ionic concentration shall include a sample bench and other
facilities for operating portable test meters. Each installation shall incorporate a valve and pipework
for obtaining a sample representative of the fluid at the position of the permanent meter, tundish
and drain. If the measuring and sampling points are remote from each other, the test and sample
539
facilities shall be provided at both points. Sample transport times shall be minimized by provision
of a bypass and drain with control and isolating valves and a local flow meter to enable the correct
sample flow to be adjusted. An automatic portable sampler shall be provided for collecting and
transporting the samples from the sampling locations to the laboratory.
6. Instrument Design Criteria
The design criteria to be applied to instrumentation system shall be as follows:
o Instrumentation & Control (I&C) systems shall be selected, designed, manufactured,

installed, tested and rated to operate under the defined performance duties and specified
site conditions and to maintain a high level of operational reliability. Instruments mounted
in field and on panels shall be suitable for continuous real time operation. All electronic
components shall be adequately rated and circuits shall be designed so that change of
component characteristics shall not affect the plant operation. All I&C equipment shall be
new, of proven design, reputed make and have data logging facility. Unless otherwise
specified, all instruments shall be tropicalized. The outdoor equipment shall be designed
to withstand tropical rain and shall be suitable for the worst environmental operating
conditions. Wherever necessary space heaters, heat dissipaters, dust and weather proof
cabinets shall be provided. Instruments offered shall be complete with all the necessary
mounting accessories & safety features.
o No custom made hybrid type integrated circuits shall be used in any circuit in
instrumentation and control equipment.
Instruments and loggers provided shall be able to carry out continuous real time monitoring
and logging of selected water quality parameters.
o All instrumentation shall be suitable for continuous real time operation and be powered
through the UPS. Wherever power supply is not available solar batteries shall be used to
Power the instruments
o The signal/data from all field mounted instruments and skid mounted instruments shall be
transmitted to the PLC through hardwired 4-20 mA / 0-10V DC linear having two/four
wire system in the respective STP/pumping stations/LS for local monitoring, control and
automation.
o The signal/data transmission from RTUs to central control room shall be GPRS/GSM
based and preferably supported with alternate land based fibre communication link.After a
power failure, when power supply resumes, the instruments and associated equipment shall
start working automatically.
o Unless otherwise specified, the normal working range of all indicating instruments shall be
between 25% and 80% of the full scale range.
o The field instruments i.e. the instruments mounted outside the control panel shall be
mounted at a convenient height of approximately 1.2 m above grade platform.
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o Unless otherwise stated, field mounted electrical and electronic instruments shall be
weatherproof to IP-65 or better.
o The instruments shall be designed to work at the ambient conditions of temperature,
humidity, and contamination that may prevail at site. The instruments shall be given
enough protection against corrosion. All wetted parts of instrument sensors shall be non –
corrosive and suitable for use within sewerage environment.
o The performance of all instruments shall be unaffected for the ±10% variation in supply
voltage and ±5% variation in frequency simultaneously.
o Unless otherwise specified, double compression glands shall be used for glanding the cable
in field instruments and instrument control panel.
o All digital outputs shall be volt freefuse protectect relay contact type
o All probe type analyzers should be IP68 rated.
o All displays shall be of the digital type with no moving parts and should utilize back lit
liquid crystal diode LCD/ LED technology.
o Instrumentation shall utilize solid state electronic technology and avoid the use where
practical of any moving parts.
o Minimum maintenance requirements. The instruments selected shall be rugged and not
require any consumables / filling solutions. Systems should be able to work with minimum
power requirements.
o Lockable enclosure shall be provided for all the field mounted instruments.
o All the instruments and cabinets shall have tag plates / name plates permanently attached
to them.
o All instruments to be used or installed within a corrosive sewerage environment shall be
explosion proof and intrinsically safe.
o The data obtained from the online quality monitoring system shall be conveyed back via
suitable communications protocol, to web servers hosted by a service provider. The service
provider shall have the data storage capacity for next 15 years.
o Unless otherwise specified, all continuous online monitoring instruments shall be plug and
play type.
o Instrumentation system shall be provided to monitor the following parameters as required–
barring all physical parameter instruments e.g. pressure, flow and temperature all other
field instrument shall preferably be mounted in analyzer room as indicated in the “Plant
Control Configuration” attached to the Scope of Works gives basic and minimum
requirement of Instrumentation and Control Automation with electrical interface.
o Online Continuous Dissolved Oxygen Measuring System
o Ultrasonic Level Measurement
o Ultrasonic Differential Level Measurement
o Flow Measurement Instrument at Parshall Flume
o Gas Flowmeter (Thermal Mass Flow Measurement System)
o Pressure Transmitter
o Continuous Online Total Suspended Solids Analyzer
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o Continuous Online pH Measuring System
o Online Residual Chlorine Measuring System
o Conductivity Meter
o Ammonia Analyzer
o Alkalinity Analyzer
o Indicative BOD Analyzer
o Indicative COD Analyzer
o Indicative TOC Analyzer
o Measurement of CO2, CH4 and H2S Gas Concentration
o Electro-Magnetic Flow Meter
o Online Gas Calorific Value Measurement
o Total Phosphorus
o Nitrate Analyzer
o Total Nitrogen Analyzer
o Flowmeter and CCTV at I&Ds
7. Online Instruments
The online measurement at Inlet and outlet for continuous monitoring of the raw and treated sewage
characteristics are specified below. However Concessionaire shall provide additional instruments
to support their design.
o At the Inlet Point and the Outlet Point –

 Electro-Magnetic Flow Meter/ Ultrasonic Open Channel Flow Measurement
 Continuous Online pH Measuring System
 Continuous Online Total Suspended Solids Analyzer
 Indicative BOD,COD,TOC Analyzer
 Total Phosphorus
 Total Nitrogen Analyzer
 Online Residual Chlorine Measuring System (at outlet point only)
All instruments shall be provided with their mounting accessories.

Online instrument system shall have the ranges in accordance with CPCB “Guidelines for
continuous monitoring for Effluents” and CPHEEO.
8. Laboratory – Laboratory instruments and sampling system
The laboratory shall be housed within the administrative building and shall be equipped with
instruments, equipment, chemicals and other infrastructure that is necessary to perform the routine
analysis for the parameters as detailed in “Table 2”. The equipment shall be supplied with all the
accessories that are necessary to make the equipment functional for analyzing parameters and
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generating daily reports. In addition to these, Concessionaire shall also provide necessary
chemicals, glassware and reagents required for sample testing in the laboratory along with
calibration standards / solutions for calibrating the instruments.
The quality of the sewage entering, passing and leaving the treatment plant shall be monitored via
online monitoring equipment as well as manual sampling systems and tested daily, at least from
the following parameters:
Table 2 – Parameters to be monitored

Sl. No Parameter
1 BOD
2 pH
3 SS
4 Temp.
5 COD
6 TOC
9 Acidity, Alkalinity
10 Ammoniacal Nitrogen
11 Total Nitrogen
12 MLSS/MLVSS
13 Dissolved Oxygen
14 SVI
15 Total Hardness, Calcium Hardness
16 Gas Analysis
17 Calorific Value Monitoring
18 Volatile Suspended Solids
19 Total Solids
20 Specific Gravity
21 Moisture Content
22 Total Coliform
23 Faecal Coliform
24 Total Dissolved Solids
25 Bacteria, Escherichia Coli
Two portable samplers shall be provided to collect composite samples for monitoring from Inlet
chamber for raw Sewage and at outlet of STP
The laboratory shall have the equipment, storage space and chemicals for all the chemical and
bacteriological routine analyses. The area of laboratory shall be sufficient with sufficient length of
working platforms and adequate no. of sinks. Area of laboratory shall be defined by Concessionaire
as per the requirement of the Concession Agreement. At least the following equipment and all
required laboratory chemicals / reagents given in Table 3 are to be provided by the Concessionaire
within the scope of work and have to be replenished by him till the end of the O&M Period.
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All lab based test instruments results shall be stored automatically/Manually and transferred to the
PLC as well as web servers on real time basis for control and report applications.
Table 3: Lab Instruments

Sl. No. Parameter
1 Comparator test set for residual chlorine or chloroscope
2 Single / Multi parameter meter for pH, Conductivity, DO, Ammonia
3 Mains operated pH meter completed with one calomel electrode and glass electrode
4 Turbidity meter - Bench Model
5 Turbidity meter - Hand held (Portable)
6 UV / VIS Spectrophotometer
7 Water bath with 6 to 8 concentric holes and discs, electrically heated
8 Hot plates – 25cm
9 Ultrapure Water Plant
10 Conductivity with TDS meter
11 Refrigerator (280 litres capacity) double door / cooling cabinet for sample preservation
12 Muffle furnace
13 Electronic Burettes and Dispensers
14 Magnetic stirrer
15 Analytical balance (Electronic) with weight box – Resolution up to 4 decimal places
16 Jar-Test apparatus – 6 Stirrers
17 Centrifuge
18 Flame photometer with gas cylinder
19 Fume cupboard
20 Field Test kit for cations and anions
21 Depth Sampler
22 Total Organic Carbon Analyser
23 Sieve shaker with standard sieves and two pan balance weighing up to 200gm samples
24 Hot Air Oven
25 Autoclave
26 Binocular microscope
27 Portable Sampler
28 Pipette Box (Stainless Steel)
29 Wooden Racks/Aluminium Racks
30 Wire Baskets
31 Cotton/ Aluminium Foils
32 Burners (Bunsen) With Pilot Lamp
33 Suction Flask (1 Litre Cap)
34 Suction Pump
35 Sampling Bottles
36 Measuring Cylinders (1000 Ml, 500 Ml, 200 Ml, 100 Ml, 50 Ml, 25 Ml)
37 Vacuum pump
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Sl. No. Parameter
38 Soxhlet extraction unit
39 Kjeldhal digestion unit
40 Weighing Balance (max 10kg)
41 Laminar Air Flow chamber
42 M. Endo Broth (dehydrated)
43 Lactose or Lauryl Tryptose broth
44 Mac Conkey broth
45 Brilliant Green Bile Lactose Broth
46 Total Plate Count Agar
47 Peptone / Triyptone Water
48 BOD Analysis: Incubator, Reagents, etc
49 COD Analysis: COD Reactor – 15 Vials, Reagents, etc
50 Filtration assembly for suspended solids
51 Incubator 44°C (Water/Air-Jacketed)
9. Online Instruments Specifications
9.1. Flow measuring system

13.1.1 Electromagnetic flowmeter
Flow meters shall operate on the electromagnetic induction principle and shall consist of a
measuring sensor and measuring transmitter complying with ISO 6817:1997. Measuring
sensors shall have a full bore stainless steel metering tube and non-conductive, abrasion-
resistant lining to suit the fluid being metered. The lining of material can be of polyurethane.
No rubber lining will be allowed. The flow meter shall have flanged connection. Measuring
sensors shall have factory sealed power and signal cables. Unless otherwise specified, the
cable lengths shall be sufficient to permit termination external to the chamber, either at a
junction box or at the measuring transmitter. Remote flow indicator cum integrator shall be
provided on the control panel.
Measuring sensors installed within a chamber shall be suitable for indefinite submersion
under a head of water equal to the chamber depth or 3 meters whichever is the greater.
Measuring sensors shall be installed on a steel cradle or concrete plinth with upstream and
downstream straight pipe lengths not less than those recommended by the manufacturer.
When fitted in lined non-metallic or internally-coated pipe work, measuring sensors shall
have an earthing electrode or corrosion resistant earthing rings. To ensure full
electromagnetic compatibility the flow tube flanges and transmitter housing shall be
connected earth.
Measuring sensors shall be bonded by tinned copper braid links at each end to the adjacent
pipe work to ensure a good connection between the body and the metered liquid. Measuring
sensors installed in a catholic protected pipeline shall have isolation and bonding in
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accordance with the recommendations of the manufacturer. The measuring transmitter shall
provide a precise current input to the field winding of the measuring sensor and shall convert
the resultant signal from the electrodes to analogue and pulse outputs in accordance with IEC
60381-1:1982. The signal processing facilities of the converter shall ensure that the output
signals are unaffected by interfering voltages, stratified flow, changes in fluid electrical
conductivity within the limit stated, non-homogeneity of the fluid and the presence of ferrous
particles. The zero and output signals shall be unaffected by partly-fouled electrodes.
The following measuring transmitter features shall be provided as a minimum:
o Measuring transmitter features:
 Pulsed D.C. field excitation

 Scaled pulse output for integration counter drive
 Capability of bi-directional measurement with differing forward and reverse ranges
and with local and remote indication of flow reversal
 Contact operation at a programmable measured value
 Integral display of flow and integrated quantity
 Galvanic isolation between each output circuit and between the electrode circuit and
output circuit
 Output circuit isolation from earth within the instrument but suitable for earthing at
any point in the external circuit
 Key entry for basic parameters
 Commissioning and re-scaling to require no special programming knowledge
 Adjustable low flow cut-off
 Self-diagnosis
 Continuously adjustable velocity and flow range settings
 Terminals accommodated in a compartment separate from electronic components
 Outputs including: analogue - 4-20mA
 Pulse - two programmable outputs
 Alarms - two outputs programmable for high/low
 Flow, polarity, forward/reverse, instrument fault, liquid sensing fault condition
including partially empty pipe
 Technical specifications
o Measuring Principal : Electromagnetic

o Type : Pulsed DC
o Application : H2S laden atmosphere and other poisonous gases,
o Corrosive Waste Water Environment
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o Safety : Explosion Proof or Intrinsically Safe
o Metering Tube : SS 304
o Sensor Housing : SS 304 fully welded
o Connection / Junction Box : SS 304
o Lining Material : PTFE/Polyurethane
o Range : As per site requirement
o Accuracy : ± 0.5% of flow rate at maximum mean velocity of 1.5 to 3.0 m/sec
o Electrode Type : Flush or bullet nose as recommended by the manufacturer
o Earthing Ring/Electrode Material: Type 316 stainless steel
o Protection Category
a.) Sensor : IP-68
b.) Transmitter / Controller : IP-67
o Transmitter / Controller Type : Microprocessor Based
o Display : Indicating and totalizing
a.) Indicator : Digital 16-character display
b.) Totalizer : Digital 16-character display
o Mounting : Pipe, wall, panel
o Diagnostic : Inbuilt
o Power Supply : 230 V AC ± 10%, 50 Hz Analog Output : Isolated 4 – 20mA / 0-10VDC
output based on the flow rate, 2SPDT Relay programmable outputZero & Span : Field
Adjustable
o Turndown Ratio : Minimum of 10 to 1 when flow velocity at minimum flow is at least 0.3
metres per second
o Zero Stability Feature : Required to eliminate the need to stop flow to check zero alignment
o Pressure Loss : Very Low
o Removable Electrodes : Required
o Flange Material : Carbon steel, Epoxy Coated
o Empty Pipe Detection : Inbuilt
o Operating Temperature : 0 to 50°C
o Repeatability : +/- 0.1 % of FSD
o Time Constant : 0.8 to 8 seconds adjustable
o Flow Data : Bi-Directional Flow with separate totalizer
For forward and Reverse FlowEmpty pipe detection with low flow cutoff
o Diagnostics : Built in with data retention in case of powerFailure.Password protection
o Temperature Compensation: Inbuilt temperature sensors for automatic compensation for
changes in air temperature
o Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.
o Certification : CE/UL Certified
13.1.2 Open Channel Ultrasonic Flowmeters

Weirs and flumes shall comply with BS 3680. An ultrasonic transducer shall measure the height of
flow before the flume or weir and, via a microprocessor based system, convert this depth reading
to flow. Computation of flow shall be to BS 3680 but the system shall allow the entry of user
547
defined data. The system accuracy shall be within ±0.5%or better of the instrument span over 5%
to 100% flow.
The flowmeter electronics shall be housed in an environmentally protected enclosure to IP 67 and
shall have a transparent front section permitting viewing of the displays and access to operator
controls. The sensor shall be protected to IP 67 or better.
The flowmeter shall be fully programmable, allowing the operator to configure the type of weir or
flume, its dimensions and flow rates. Displays shall be LCD, allowing display of flows, operating
parameters, programming details and fault data.
The output shall be 4 to 20 mA proportional to flow volt-free pulse output, Mechanical Relay
contact,
The flow meter shall have online diagnostic facility. Flow meter shall have low flow cut off for
velocity 0 to 5 m/s configurable. Flow meter shall be CE/UL Certified
9.2. Level measuring system
9.2.1. Ultrasonic/Radar level meters
Ultrasonic/Radar level measuring devices applied for liquid level measurement shall comprise of
level sensor / transducer, level transmitter, digital level indicator / remote indicator, control unit
and any other items required to complete the level measuring system.
The transducer shall be suitable for flange or bracket mounting as required. To reduce the effect of
sewage turbulence in wet wells / tanks, averaging facility should be provided in the transmitter unit
for providing steady readings.
The design and application of the ultrasonic/Radar level measuring system shall take into account
the vessel / sump / wet well / channel construction, the material, size, shape, environment, process
fluid or material, the presence of foam, granules, size etc.
In case of ultrasonic level sensor, the installation shall avoid any degradation of instrument
performance due to spurious reflections, absorption, sound velocity variations, sensor detection
area, temperature fluctuations, specific gravity changes and condensation. For applications where
spurious reflections are unavoidable the control unit shall be provided with facilities for spurious
reflection rejection. If turbulence exists, shielding, stilling tubes or other measures shall be provided
to avoid effects on the measurement.
o Measuring Principal : Ultrasonic

o Application : H2S laden atmosphere and other poisonous gases, corrosive Waste Water
Environment
o Range : As required at site
o Accuracy : ± 0.25% of measured value or better
548
o Resolution : 2mm or 0.2 percent of range, whichever is greater
o Blanking Distance : As short as 0.3 meters
o Beam Angle : 12 degrees or less
o Temperature compensation : Integral
o Mounting
a.) Sensor : Flange or bracket
b.) Transmitter / Controller : Wall, Panel, Pole
a.) Sensor : IP-68
b.) Transmitter / Controller : IP-67 (NEMA 4X)
o Display : LCD with LED backlighting 130
o Power Supply : 230 V AC ± 10%, 50 Hz
o Analog Output : Isolated 4 – 20mA
o Relay Contacts : Minimum of 3 SPDT contacts
o Zero & Span : Field Adjustable
o Sensor Cable : Integral to sensor
o Cable Length : As per site requirement
Technical specifications for Radar Level Transmitter
o Measuring Principal:Radar / Guided wave Radar

o Application:H2S laden atmosphere and other poisonous gases,Corrosive Waste Water
Environment
Safety: Explosion Proof or Intrinsically Safe
o Range: As required at site
o Accuracy:± 0.25% of measured value or better
o Resolution: 2mm or 0.2 percent of range, whichever is greater
o Blanking Distance: As short as 0.3 meters
o Temperature compensation:Integral Mounting
o Sensor:Flange or bracket
o Transmitter / Controller :Wall, Panel, Pole Protection Category
o Sensor :IP-68
o Transmitter / Controller :IP-67(NEMA 4X)
o Transmitter / Controller Type:Microprocessor Based
o Diagnostic:Inbuilt
o Display :LCD with LED backlighting 2 Line 16 characters
o Cable Entry : ½” NPT
o Power Supply :230 V AC ± 10%, 50 Hz
o Analog Output:Isolated 4 – 20mA with HART
o Relay Contacts: Minimum of 3 SPDT contacts
o Zero & Span: Field Adjustable
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o Operating Temperature:0 to 50°C
o Resolution : 0.01 mA
o Housing Material : Die cast Aluminium
o Communication Protocol:Open Protocol like HART,MODBUS, PROFIBUS, etc.
o Sensor Cable:Integral to sensor
o Cable Length:As per site requirement
9.2.2. Ultrasonic differential level measurement
The ultrasonic type differential level measuring system shall consist of ultrasonic type level sensors
on upstream and downstream of screens, differential level computer / transmitter and indicator. The
flow computer / transmitter shall be microprocessor based and shall have facility for programming
(i.e. adjustment of set points) while the sensor shall be capable of adjustable datum setting facilities.
The differential level control shall be done by two ultrasonic sensors, one before and one after the
screen to sense the differential level through the screen and give a signal to the control to start the
screens operation as soon as a preset differential level is reached. After receiving the level signal
the control shall start and operate the screen as long as the preset level difference appears.
o Measuring Principal : Ultrasonic

o Accuracy : ± 0.25% of measured value or better
o Resolution : 2mm or 0.2 percent of range, whichever is greater
o Blanking Distance : As short as 0.3 meters
o Beam Angle : 12 degrees or less
o Temperature compensation : Inbuilt
o Mounting
a.) Sensor : Flange or bracket
a.) Sensor : IP-68
o Display : LCD with LED backlighting
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o Zero & Span : Field Adjustable
o Operating Temperature : 0 to 50°C 131
9.3. Pressure measuring system Pressure transmitter
Pressure measuring system shall measure pressure and transmit signal proportional to pressure.
The system shall consist of a combined pressure transducer and transmitter, digital panel indicator,
connecting pipe work, diaphragm seal and valves. Pressure measuring system shall be rugged in
construction and shall be capable for with standing surge pressures likely to occur in the monitored
system. Pressure transmitters shall have over range protection up to 1.5 times the maximum line
pressure and shall be capable of withstanding full line pressure on any side with the other side
vented to atmosphere without damage or effect on the calibration. No plastic material shall be used
in their construction. Internal parts shall be of stainless steel, bronze or approved corrosion-resistant
material. Where necessary, a special diaphragm shall be used to segregate the corrosive fluid media.
In ammonia applications, the diaphragm shall be in stainless steel. In chlorine applications, the
diaphragm shall be in silver or tantalum. In Sulphur dioxide applications, the diaphragm shall be in
tantalum.
The zero and span of a pressure transmitter shall not change by more than ±0.1% of the span per
°C change in ambient temperature. After application for 10 minutes of pressure at 130% of
maximum pressure, the change in zero and span shall not exceed ±0.1% of the span. Pressure
transmitters shall be protected to BS EN 60529:1992, IP 65 standard or higher. For transmitters
installed in locations liable to flooding or underwater applications, they shall be to IP 68 standard
and shall operate up to a maximum submergence of 20 meters of water.
Note: Explosion proof and intrinsically safe transmitters/instruments are required only for
instruments/sensor/limit switches/solenoid valves located in the hazardous areas and not for
instruments/sensor/limit switches/solenoid valves located in Safe Areas.
Instruments in hazardous area installation shall be intrinsically safe and in case of

instruments where intrinsically safe option is unavailable, explosion proof shall be provided
o Parts : Transmitter and communicator

o Type :;Smart two-wire transmitter
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o Application : H2S laden atmosphere and other poisonous gases, Corrosive Waste Water
Environment
o Accuracy : ± 0.25% of span or better
o Humidity : 0 to 100% relative humidity
o Damping : Fluid or electronic type with adjustment
o Indicator : LCD with LED backlighting
o Materials : Wetted parts including process flanges and drain / vent valves, Type 316
stainless steel otherwise specified
o Wetted O-Rings : Glass filled TFE, graphite filled PTFE, or Viton, unless otherwise
specified
o Fill Fluid : Silicone
o Output : 4 – 20mA DC output proportional to the pressure range
o Mounting : Pipe or wall as specified. Provide stainless steel brackets with stainless steel
bolts
o Housing : Modular with separate compartments for
electronics and field wiring termination. Epoxy coated aluminium, unless otherwise specified
o Power Supply : 24 VDC Loop powered / 230 V AC ± 10%, 50 Hz
o Span & Zero Adjustment : Local & Remote
o Stability : +/-0.1% of URL for 10 years
o Communication Protocol : Open Protocol like HART,MODBUS, PROFIBUS, etc.
Pressure Gauges
o Pressure gauges shall comply with BSEN Standard or higher. Pressure gauges shall
have over range protection up to 1.5 timesthe maximum anticipated linepressure
o Internal parts shall be of stainless steel, bronze or other corrosion resistantmaterial
o All pressure gauges shall be supplied complete with isolating valves and calibration points
to enable calibration or removal without loss offluid.
o Where compensation of more than 2% of the instrument span is needed for the difference
in level between the instrument and the tapping point, the reading shallbe suitably adjusted
and the amount of compensation marked upon the dial. The instrument shall be provided
with a micrometer screw for zero adjustment. The dial shall have 150 size with white
background and scale in blackcolour
9.4. Dissolved oxygen measuring system - DO analyzer
DO analyzers shall be installed to continually record the dissolved oxygen level at every grid within
each aeration basin. The primary sensing device used for the dissolved oxygen level measurement,
shall be a sensing probe mounted within the aeration basin and connected to a controller for
displaying and transmitting the results
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o Measuring Principal : Optical

Environment
o Range : 0 to 20.0 ppm, 0 to 20.0 mg/L
o Accuracy : ± 0.5% or better
o Repeatability : ±0.5% of span
o Sensitivity : ±0.5% of span
o Pressure Limit : 4 - 6 bar
o Temperature Indication : Inbuilt
o Calibration Method : Air Calibration: One point, 100% water saturated air;
o Sample Calibration: Comparison to standard instrument, or comparison to Winkler
Titration method
o Cleaning : Air Blast Unit. Probe should be able to function with cleaning unit attached to
it
o Mounting
a.) Sensor : Inside aeration basin at each grid
a.) Sensor : IP-68 for Sensor
o Relay Contacts : Minimum of 2 SPDT contacts 133
9.5. Total Suspended Solids Measuring System - TSS Analyzer
o Measuring Principal : Optical
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Environment
o Range : 0 - 1000 mg/l, 0 – 5000 mg/l
o Accuracy : <5% of reading or better
o Pressure Limit : 6 bar
o Flow Rate : Maximum 3m per second
o Calibration Method : Single point or two point
o Cleaning : Inbuilt
o Mounting
a.) Sensor : Inside pipe / channel / tank
a.) Sensor : IP-68 for Sensor
o pH Measuring System – pH Analyzer
9.6. pH measuring system- pH Analyzer
o Measuring Principal : Combination / Differential Electrode

Environment
o Range : 0 - 14 pH
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o Accuracy : ±0.02 pH or better
o Repeatability : ±0.05 pH
o Sensitivity : ±0.01 pH
o Pressure Limit : 4 - 6 bar
o Temperature Compensation : Inbuilt automatic temperature compensation
o Temperature Accuracy : ±0.5 °C
o Calibration Method : Two point automatic, one point automatic, two point manual, one
point manual
o Mounting
o For Transmitter / Controller : IP-66 (NEMA 4X)
9.7. Residual Chlorine Measuring System – Residual Chlorine Analyzer
o Measuring Principal : Amperometric or DPD Colorimetric

Environment
o Range : 0.00 to 20 PPM
o Accuracy : ±3% of the reference test or better
o Resolution : 0.001 ppm
o Repeatability : 30 ppb or 3%, whichever is greater
o pH : Automatic
o Temperature Compensation : Inbuilt temperature sensor
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o Pressure Limit : 0.5 bar
o Flow Rate : Maximum 50 L/hour
o Calibration Method : 1-point or 2-point calibration
o Mounting : Wall, Panel
a.) Sensor : IP-65
o Analog Output : Isolated 4 – 20 mA
9.8. Conductivity Measurement – Conductivity Analyzer
Environment
o Range : 0 - 1000 μS/cm
o Accuracy : ±0.5% or better
o Temperature Compensation : Inbuilt
o Mounting
o For Transmitter / Controller : IP-66 (NEMA 4X)
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9.9. Ammonia Measurement - Ammonia Analyzer
Environment
o Range : 0 – 5 mg/l, 0 - 50 mg/l
o Accuracy : 3% ±1mg/l or better
o Repeatability : 2% ±1mg/l or better
o Flow Rate : Maximum 20 L/h
o Cleaning : Automatic
o Mounting
a.) Analyzer : Wall, Panel
a.) Analyzer : IP-55 or better
b.) Transmitter / Controller : IP-66 or better
9.10. Alkalinity Measurement – Alkalinity Analyzer
Environment
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o Range : 0 – 500 mg/l
o Accuracy : ±5% of reading or ±1.0 mg/L, whichever is greater
o Repeatability : ±3% of reading or ±0.6 mg/L, whichever is greater
o Pressure Limit : 2 bar
o Flow Rate : Maximum 2 L/m
o Mounting : Wall, Panel
o Protection Category : IP-66 (NEMA 4X)
o Operating Temperature : 0 to 50°C 137
9.11. Total Nitrogen Measurement – Total Nitrogen Analyzer
o Measuring Principle : UV Absorption

Environment
o Range : 0 - 80 mg/l
o Accuracy : ± 3% of mean + 0.5 mg/l
o Resolution : 0.1 mg/L
o Mounting
a.) Sensor : IP-68
o Analog Output : Isolated 4 – 20 mA
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9.12. BOD Measurement – Indicative BOD Analyzer

o Range : 0 - 500 mg/l
o Accuracy : ± 5% or better
o Compensation : 550 nm
o Sample pH : 4.5 to 9 pH
o Cleaning : Automatic 138
o Mounting
a.) Sensor : IP-68
9.13. COD Measurement – Indicative COD Analyzer

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o Range : 0 - 1000 mg/l
o Mounting
a.) Sensor : IP-55 or better
9.14. TOC Measurement – Indicative TOC Analyzer
o Measuring Principle : UV Absorption / UV Pursulphate

o Range : 0 - 1000 mg/l
o Mounting
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a.) Sensor : IP-55 or better
13.15.Total Phosphorus Measurement – Phosphorus Analyzer

Technical specifications
o Measuring Principle:Photometric
o Application:H2S laden atmosphere and other poisonous gases,
Corrosive Waste Water Environment
o Safety: Explosion Proof or Intrinsically Safe
o Range: 0 - 10 mg/l
o Accuracy:2% of the measured value + 0.05 mg/L or better
o Repeatability:2% of the measured value + 0.05 mg/L
o Flow Rate:Maximum 20 L/h
o Sample pH:5 to 9 pH
o Pressure Limit: 0.05 bar
o Mounting
a) Analyzer:Wall, Panel
o b) Transmitter / Controller:Wall, Panel, Pole
a) Analyzer:IP-55 or better
o b) Transmitter / Controller:IP-55 or better
o Transmitter / Controller Type :Microprocessor Based
o Display :LCD with LED backlighting
o Power Supply: 230 V AC ± 10%, 50 Hz
o Analog Output:Isolated 4 – 20mA
o Relay Contacts :Minimum of 2 SPDT contacts
o Operating Temperature :0 to 50°C
o Communication Protocol: Open Protocol like MODBUS, PROFIBUS, etc.
o Cable Length: As per site requirement
13.16 Nitrate Measurement – Nitrate Analyzer

Technical specifications
o Measuring Principle: UV Absorption
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o Application: H2S laden atmosphere and other poisonous gases,
Corrosive Waste Water Environment
o Safety: Explosion Proof or Intrinsically Safe
o Range: 0 – 30 mg/l, 0 - 80 mg/l
o Accuracy:± 5% or better
o Resolution:0.1 mg/L
o Pressure Limit: 0.5 bar
o Mounting
a) Sensor: Inside pipe / channel / tank
b)Transmitter / Controller:Wall, Panel, Pole
a) Sensor: IP-68
b) Transmitter / Controller:IP-66 (NEMA 4X)
o Transmitter / Controller Type:Microprocessor Based

o Display :LCD with LED backlighting
o Power Supply: 230 V AC ± 10%, 50 Hz
o Analog Output:Isolated 4 – 20mA
o Relay Contacts:Minimum of 2 SPDT contacts
o Operating Temperature :0 to 50°C
o Communication Protocol:Open Protocol like MODBUS, PROFIBUS, etc.
o Sensor Cable:Integral to sensor
o Cable Length :As per site requirement
10. Surge Protection Devices
Surge protection devices (SPDs) shall be suitable for withstanding the surge arising out of high
energy static discharge / lighting strikes and protect the instrument to which it is connected against
damage. SPDs shall provide protection through the use of quick acting semiconductors like
Tranzorb, zener diodes, varistors and an automatic disconnect and reset circuit. SPDs shall be
passive and shall require negligible power for operation. During the occurrence of a surge it shall
clamp on the allowable voltage and pass the excess voltage to the ground. The SPD shall be self
resetting to minimize the down time of the measurement loop.
SPDs shall be provided to protect devices transmitting and receiving analogue and digital signals
derived from field devices located outdoors.
The surge protection device shall be rated for surge rating of 10kA.
11. Cabinets for field instruments
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Wall mounted cabinets shall be provided for enclosing transducer unit and associated accessories
which are mounted outside the main control panel. The cabinet shall be of die-cast aluminium;
field provided not less than IP-65 protection and shall be lockable. The cabinet shall have facilities
for earthing. A steel plate shall be provided inside the cabinet for mounting instrument and
accessories.
12. Panel Details
12.1. Cabinet / Enclosure for Instruments
Enclosures shall be any form of board, cabinet, panel, desk, box or case used to protect, contain or
group instrumentation, telemetry or control equipment. Cabinets shall be fabricated from cold
rolled steel with powder coating sheet of minimum 2 mm thick and shall be suitable for wall
mounting or pedestal mounting as required. A steel plate/pipe, as per the requirement, shall be
provided in the cabinet for mounting the instrument and accessories. The cabinet shall be properly
painted from inside and outside and shall have built in locking facility. The cabinet shall also be
earthed properly. All equipment in or on enclosures shall be arranged logically and, as far as
possible, symmetrically, with projections kept to a minimum. Each enclosure shall be designed on
ergonomic principles and shall permit in-situ and safe access for any normal adjustment,
maintenance and servicing. The tops of plant-mounted enclosures shall be sloped downwards from
front to rear.
The minimum degree of protection shall be IP 54 for indoor locations and enclosures for use outside
buildings or in places where splashing may occur shall have a minimum rating of protection to BS
EN 60529:1992, IP 65 and have tops which project sufficiently to protect the vertical faces of the
enclosure and any component mounted thereon from splashing, inclement weather and direct
sunlight. Also, when enclosures for use outside buildings are located where exposure to direct
sunlight will give rise to high top-panel surface temperatures such that the internal temperature
rises above the manufacturer’s recommendation (normally 40°C), the enclosure shall include a sun
shield fitted to the top of the enclosure and should have sufficient air ventilation for heat dissipation.
Fixing arrangements for surface-mounting enclosures shall be external to the enclosure and shall
ensure that the rear face of the enclosure is not in contact with the surface to which it is fixed.
Enclosures shall have hinged access doors, fitted with recessed lockable handles. Doors shall be of
rigid construction and provided with close-fitting flexible seals in recesses to prevent the ingress
of liquids, moisture, dust and vermin. Hinges shall be of the lift-off pattern and one hinge shall
engage before the other for ease of fitting. Wherever necessary, removable access covers secured
by quick-release fasteners shall be provided to ensure ease of maintenance for all installed
apparatus. Mounting plates, brackets and racks shall be provided for all other internal equipment
which shall be hinged or otherwise arranged with quick-release fasteners or captive screws to give
quick and easy access to equipment, securing screws, terminals and wiring.
Enclosures for two or more devices with electrical circuits shall have gland plates and terminal
blocks as specified elsewhere. Each enclosure shall be designed for the safe testing and servicing
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of equipment with the power on. Each part which may be live under any circumstances shall be so
covered or shielded as to prevent inadvertent contact.
12.2. Panel Design and Construction
Unless otherwise specified, all instrument panels, instrument cubicles, control panels, control
consoles and desks, associated equipment and terminal racks, telemetry and electronic equipment
racks and the like shall be free-standing, floor-mounted units and shall conform to the requirements
of this part and will hereafter be referred to as panels. The design and dimensions of control
consoles and desks shall be determined according to their intended function but shall be in
accordance with the requirements of the Specification drawings. The height shall not exceed
1400mm above the finished floor level.
Unless otherwise specified as per the approved Design and Drawings, the height of panels shall be
not greater than 2130mm overall (excluding lifting devices) above finished floor level. Front of-
panel instruments and controls shall be mounted so that the height of their centers above the floor
shall be generally between 1800mm and 900mm for indicators, 1400mm and 900mm for recorders
and process controllers, 2000mm and 750mm for alarm facias and signal lamps and 1500mm and
750mm for manual controls. Controls, switches and push-buttons shall be positioned below or
adjacent to any associated reading instrument. Panels for use in locations such as pumping stations
and machinery rooms shall have anti-vibration mountings. The clearance between the extremities
of apparatus mounted on the internal walls shall allow safe and unobstructed access to all terminals
and to parts requiring maintenance. Panel layout drawings shall normally include a list of all
instruments, accessories and components contained therein. If the drawings have insufficient space
for the list, a separate schedule of instruments, accessories and components shall be provided and
the panel drawing shall contain a cross reference to the contents list and an indication of the panel
location of each item on the list.
12.3. Panels - major
Panels shall be constructed generally as specified in the preceding clause and as shown in the
Specification drawings. Panel material shall be prime-quality, cold-rolled and annealed mild steel
or zinc-coated mild steel sheet, suitably braced and stiffened as necessary with flat bar or angle to
form a rigid structure.
Panel fronts shall be flat and free from bow or ripple. Exterior corners and edges shall be rounded
or welded and ground to give a smooth overall appearance. Flanged edges shall be straight and
smooth. Materials shall be chosen with due regard to the panel size, number of cut-outs, instrument
weight and position of centre of gravity and method of fabrication, with the following:
o minimum thicknesses
 Instrument bearing surfaces, gland plates and pneumatic distribution plates: 3mm
 Internal mounting plates: 3mm
 Doors, covers and filler panels: 2mm
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No design involving the use of externally-visible assembly or fixing bolts and screws nor any
design resulting in dust or water-collecting crevices will be accepted. Stiffeners and supporting
frameworks shall be provided where necessary inside panels. Framework shall be hinged or fixed,
suitable for the installation of instruments, components and internal equipment for which it is
provided and located to give easy access to adjacent equipment.
When a panel is constructed in sections, the sections shall be designed for ease of assembly during
installation and, in any case, shall not exceed 2 m in length. All necessary nuts, bolts, washers and
the like shall be supplied and included in the same shipment as the relevant sections. Sections
exceeding 1 m in length shall be provided with double doors. Unless otherwise shown in the
Specification drawings, each panel shall be mounted on a self-draining base frame fabricated from
150 mm deep, steel channel section which shall be drilled or provided with clamps for bolting to
the floor. The base frame shall be set back from the panel front face to give a toe space of not less
than 25mm. The outside of the base frame shall be covered with an approved kicking strip.
Ceiling and other filler panels shall be fabricated from sheet steel and adequately stiffened. Each
section shall have 50 mm returned edges along all four sides and shall be braced to the main
steelwork of the panel. A chequered plate floor shall be provided inside and above the level of the
base frame, having openings suitable for the bottom entry of cables when applicable. Sufficient
removable undrilled gland plates, in sections convenient for handling, shall be fitted close to the
appropriate terminal blocks and not less than 230 mm above the panel floor or not less than 230
mm below the panel top. The gland plates shall have removable side covers giving access to both
sides of the gland plate and ensuring vermin-proof and dust-proof construction. Gland plates of a
surface-mounted enclosure may form a part of the base or top. Panels containing pneumatic or other
instruments using a fluid as the transmission medium shall have distribution plates with bulkhead
unions for the termination of internal and external pipework.
All doors shall open outwards and all doors in one panel assembly shall use the same lock and key
combination. Panel design shall ensure adequate ventilation and air circulation without permitting
the entry of vermin or dust. Panels installed in control rooms or other clean condition areas shall
have louvres to allow air circulation. Temporary closures shall be provided to prevent the entry of
dust and vermin during transit and installation. After commissioning has been completed, all entries
except air-circulation louvres shall be sealed.
No equipment other than front-of-panel items shall be mounted on panel wall surfaces. If electrical
and non-electrical instruments are mounted in the same panel, the panel shall be subdivided
internally to separate the electrical and non-electrical sections. All connections shall be arranged to
ensure that no accidental damage to cabling or electrical components can occur in the event of
failure of any non-electrical component or connection. Provision shall be made for safe and easy
handling during transit and installation. If lifting eyes are provided, they shall be reversible and
panel tops shall be reinforced where necessary.
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Where equipment is specified to be installed at a future date, space shall be allocated, and cutouts
with removable masking plates, brackets, supports, wiring, terminals and piping and the like shall
be provided. Panels shall be finish-coated at the place of manufacture before commencing the
installation of apparatus and other fittings.
12.4. Panels - Minor
Panels for installation on the Plant which contain relatively few items of equipment, or where so
specified elsewhere, shall be provided s minor panels and shall be constructed generally as specified
in the preceding clause and comply with this Clause. Panels shall be fabricated from sheet steel or
other approved material less than 2.5mm thick suitably braced to form a robust and rigid structure.
Exterior corners and edges shall be rounded to give a smooth overall appearance and assembly
bolts, screws or rivets shall not be visible on the front face.
The design shall be such as to ensure adequate ventilation and air circulation where required,
without permitting the entry of vermin. Openings for cables shall be made vermin-proof. Doors
shall be hinged and shall be provided with close-fitting flexible seals in recesses to prevent the
ingress of liquids, moisture, dust and vermin. Unless otherwise specified, panels shall be suitable
for floor mounting and shall not exceed 2130mm in height. Where surface mounted panels are
provided, the fixing shall prevent the ingress of moisture and the rear of the enclosure shall be not
less than 10mm from the wall.
Lifting eyebolts shall be removed and replaced with bolts after installation. Panels shall be
extensible, and symmetrically arranged as far as possible with projections kept to a minimum.
Where two or more panels are fitted together, they shall form a flush-fronted continuous panel of
uniform height. Front door and top cover dimensions shall match. Instruments, relays, and control
devices shall be mounted at a height not more than 2000mm and not less than 300mm from floor
level.
The arrangement of equipment within each enclosure shall be such as to permit easy access for
installation and maintenance. No instruments, relays or other components shall be mounted on rear
access doors or removable covers.
12.5. Panels - composite
In situations where space limitations preclude the use of separate instrumentation, control and
automation (ICA) and switchgear panels and with prior approval of the consultant ICA equipment
may be combined within a single enclosure subject to the following conditions:
Enclosure
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o The observance of all other clauses herein relating to enclosures, mounting boards and minor
panels.
o The written assurance of each supplier of ICA equipment that the proximity of the switchgear
will have no detrimental effect on the life or performance of any ICA component
o The total segregation of ICA equipment and switchgear including the glanding and termination
facilities.
o The absence of any voltage exceeding 250V ac or 50V dc from any compartment containing
ICA equipment.
o The use of the full height of the panel (excluding the busbar chamber and cable space) for any
ICA equipment compartment.
12.6. Panels - Glass Reinforced Plastic (GRP)
Any panel required to be installed outside buildings shall be manufactured from double-skin, resin-
bonded fibreglass, with a totally encapsulated infill of rigid weatherproof and ‘boil proof’ plywood
to BS 1203:2001 between the two skins to provide a rigid and vandal-proof enclosure.
The environmental rating shall be IP 65 or better.
For any application in a non-temperate climate or where so specified elsewhere, the roof section
shall be sloping and have a totally-encapsulated infill of end-grain balsa instead of plywood. Box
section steel shall be encapsulated into door edges and door frames. Door locks, handles and hinges
shall be of a high tensile strength, non-corroding alloy with stainless steel pins and through fixing
bolts. Large plane surfaces shall have adequate reinforcing to ensure rigidity.
The doors shall be complete with latching handles and locks. All door catches and locks shall latch
onto steel-reinforced surfaces. Threaded studs shall be incorporated into the design of the panel for
the mounting of sub frames within the panel. Any panel drilled to provide fixings for internal
equipment will not be accepted. Each cubicle shall be provided with a floor or deck with a
removable gland plate for cable entry.
The laminate material shall have flame-retardant characteristics in compliance with BS 476 Class
2, and shall retain ‘stability, integrity and insulation’ for 30 minutes. Colour-impregnated gel coats
backed by coloured resin shall be used to ensure maintenance free and ‘colour-fast’ finishes. The
internal finish colour shall be white. The fronts of externally-visible instruments and windows shall
be of glass. An air-gap of 100mm shall be provided between the top surface of the panel and its
protective canopy. All internal equipment shall be mounted on supports built into the fiberglass
structure. Fixing bolts through the skin will not be accepted.
12.7. Panel protection
Adequate facilities for isolation and protection by miniature circuit breaker or fuse for each
instrumentation and control circuit and sub-circuit shall be provided and shall be so arranged that
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any interruption causes minimum disruption of plant, operates the appropriate alarm and cannot
result in any unsafe operating condition. All fuses shall be of the cartridge pattern and main fuses
shall be of the high rupturing capacity type. Fuse and solid-link carriers and bases shall be of plastic-
moulded insulating material as per best industry practices. Ceramic materials will not be accepted.
Live connections shall be efficiently shrouded and it shall be possible to change fuses with power
on without danger of contact with live metal. The fuses shall be rated to give maximum protection
to the equipment in circuit and the rating shall be permanently inscribed on the fuse label and on
the fuse carrier.
Unless necessary for the protection of particular equipment, miniature circuit breakers used for
individual circuits in a panel or control desk shall not trip on over-voltage or under-voltage. Bases
for solid links shall not be interchangeable with those for fuses. Fuses and links in the same circuit
shall be mounted opposite each other in separate adjacent rows and shall not alternate in the same
row. At least 10% and not less than two unallocated miniature circuit breakers or fuses and links
shall be provided in each panel distribution board. Miniature circuit breakers and fuses of similar
size and rating shall be of the same make and type. At least 10%, and not less than two, spare fuses
and links of each rating shall be provided and fitted in clips inside the panel.
Each instrument requiring a power supply shall be individually wired and protected so that, in the
event of a failure in one circuit, the remainder is unaffected. Power supply circuits shall be of
sufficient rating that any protective device may operate without reducing the voltage at the
terminals of any other component to an unacceptable level. Remote alarms shall be operated on
failure of the electrical supply to a panel or to any internal sub-circuit. Clearly identifiable, switched
socket outlets of 15A minimum rating to comply with IS 4615, supplied at the main cabinet
operating voltages shall be fitted within the panel at the rate of one for each operating voltage per
meter of panel length; for a panel whose length is less than one meter, one switched socket outlet
for each main operating voltage shall be provided. Suitable socket outlets for portable tools and
hand lamps shall be provided as specified elsewhere.
12.8. Panel isolation
Clearly-labelled isolating circuit breakers shall be provided for each incoming power supply.
Switches shall be of the quick make-and-break type with spring-loaded contacts that close fully
without requiring full operation of the handle. The handle and cover shall be interlocked so that the
handle cannot be operated when the cover is open and the cover cannot be opened unless the switch
is in the ‘off’ position. The ‘on’ and ‘off’ positions of each switch shall be indicated clearly.
Circuit breakers for panel power supplies shall be mounted near an access point and in positions
where they may be operated easily from a standing position. Plug-in isolating links or devices of
an approved type shall be provided in any circuit that may still be alive when the power supply
isolators are in the ‘off’ position, as, for example, in circuits controlling equipment whose power
supply is independent of the panel. Such links or devices shall be properly screened and, if not
incorporated in or adjacent to their associated outgoing terminals, shall be labelled with suitable
warning notices. Any item of panel equipment to which panel internal wiring is connected with a
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plug and socket instead of terminals shall be wired in flexible cable of adequate rating between the
‘free’ plug and a socket mounted adjacent to the device. The power supply connector shall be a
socket.
12.9. Panel terminal blocks
External wiring for panel power supplies shall be terminated on the appropriate isolator. Signal
cables from strain gauges, analyzers, resistance thermometers, re-transmitting slide wires and
thermocouples may be terminated at their appropriate instruments. A terminal block shall be
provided as the interface between the corresponding conductors of each internal and external wire
and each internal and external connection except those listed above. The terminal blocks shall be
mounted vertically where possible and not nearer than 230mm to the floor or less than 230mm from
an incoming cable gland.
Terminal block rows shall be spaced apart by not less than 150mm and arranged to permit
convenient access to wires and terminals and to enable ferrule numbers to be read without difficulty.
Other circuits shall be grouped on the terminal blocks according to the classification given in the
clause for ‘Panel internal wiring’ which shall be clearly marked along the corresponding section of
each terminal board. Groups of different voltages on the same board shall be separated by insulated
barriers.
All connections shall be made from the front of terminal blocks and no live metal shall be exposed
at the back. All terminal blocks shall be of the type which clamps the wire securely and without
damage between two plates by means of a captive screw and which permits removal of any terminal
without disturbance to adjacent terminals. Pinch-screw type terminal blocks will not be accepted.
Terminal mouldings shall be in melamine to ISO 2112:1990, polyamide or equivalent. Terminal
rails shall be hot-dip galvanized. Current bars between the two connection points of each terminal
block shall be of copper or brass with tin/lead alloy plating. All steel parts shall be zinc-plated and
passivated with a yellow chromate layer.
Terminal blocks for input and output analogue signals and for circuits containing volt-free contacts
internal or external to the cabinet shall be of the Klippon type SAKC or equivalent which permit
the connection of a test millimeter or continuity meter without disconnecting any wiring.
Terminal blocks for power supplies for equipment external to the panel shall permit the isolation
of the item of external equipment without affecting the operation of any other circuit within or
outside the panel.
No more than one core of external cables or one internal wire shall be connected to any terminal.
If terminal blocks are used as common points for two or more circuits, individual terminals with
the appropriate number of permanent cross-connections shall be provided. The lengths of exposed
cable cores shall be sufficient to reach any terminal in the appropriate row or rows. The cores shall
be formed into a neat loom and a separate loom shall be provided for each cable.
569
Identification ferrules as specified in the clause for ‘Panel wiring identification and termination’
shall be fitted on each core of all external cables and on each internal wire. The size of the terminals
shall be appropriate to the size and rating of the cable cores which will be connected to them but
shall not be smaller than Klippon type SAK2.5 or equivalent.
Each row of terminal blocks shall contain at least 25% spare terminals over the number required
for terminating all cores of external cables in that row. Unless otherwise specified or shown in the
Specification drawings, each external cable shall contain at least 20% spare circuits, with a
minimum of one spare circuit. Terminal blocks shall be numbered consecutively in a sequence
different from that used for identifying wiring. The terminal numbers, voltage grouping and
terminal board layout shall correspond precisely with wiring diagrams so that quick and accurate
identification of wiring can be made. All the terminal boards shall be provided with covers of
transparent insulating material that does not sustain combustion and shall be sectionalized where
possible to give access to groups of terminals without uncovering all boards. Terminals which may
be live when the panel is isolated from its main supplies shall be suitably labelled to minimize the
risk of accidental contact.
12.10. Panel internal wiring
Panel circuits shall be segregated into the following categories:
o Group 1: Power control and very-high-level signal wiring (above 50V):

 AC power supplies
 DC power supplies
 DC current signals above 50mA (such as CT circuits)
 AC voltage and control signals above 50V (such as PT circuits)
o Group 2: High-level signal wiring (6V to 50V dc):

 Signals from conventional electronic transmitters and controllers (such as 4mA to
20mA)
 Circuits to alarm enunciators and other solid-state devices (excluding those in
categories 2.1, 2.5, 3.1, 3.2 and 3.3)
 Digital signals
 Emergency shut-down and tripping circuits
 On / Off control circuits
 Intrinsically safe circuits
 Speech-frequency circuits
o Group 3: Low-level signal wiring (5V dc and below):

 Signals from thermocouples
 Signals from resistance thermometers and re-transmitting slide-wires
 Signals from analytical equipment and strain gauges
570
For Group 3 wiring, internal connections to the instruments shall be made by one of the
following methods:
 The twisted, screened conductors of the external cable shall be led direct to their
appropriate instruments via ducting systems installed for this purpose during
construction of the panel.
 The conductors of the external cables shall be terminated on terminals segregated
from all other categories and the connections to the appropriate instruments shall be
made using twisted pairs with individual screening installed for this purpose during
construction of the panel.
Internal wiring for all circuits in Group 2 except those sharing a common connection shall be multi-
stranded, twisted pair, 0.75mm² minimum copper conductors with HPDE or PVC insulated cable
of adequate grade and rating in accordance with BS 6004:2000. Wiring for circuits in other Groups
or sharing a common connection shall be run in stranded, 1.0mm² minimum copper conductors
with 250V grade, PVC-insulated cable of adequate grade and rating. Wiring sheath colours shall
be black for AC circuits, and grey for DC circuits (excluding thermocouple circuits) and blue for
Group 2.6 circuits. Circuits supplied at 240V, between 240V and 110V dc shall also be physically
segregated from each other and from other circuits. Access to wiring and components of circuits
having voltages exceeding 240V shall not be possible unless and until the circuit has been isolated.
Separate ducts, trunking, cable looms, tray work and the like shall be provided within the panel for
each category with at least 150mm between parallel paths of Group 1 and those of any other Group.
Intrinsically-safe circuits and their terminals shall be segregated from other circuits and terminals.
All wiring shall be neatly and securely fixed by insulated cleats, bunched and secured by approved
plastic strapping or run in approved insulated wiring trunking or non-corrodible flexible tubing.
Not more than 75% of the capacity of trunking, ducts, looming, or tubing shall be used. Insulated
earth wiring shall be so arranged that access to any equipment or connection point or the removal
of any item of equipment is unimpeded. Wiring for future equipment shall be secured and
terminated on terminal blocks. Lacing for wiring looms shall be of rot-proof cord or plastic strips.
Inter-section wiring in multi-section cabinets shall be via a terminal block in each section.
12.11. Panel wiring identification and termination
Identification ferrules shall be fitted at both ends of each wire. The numbers or letters used shall
correspond with the appropriate wiring diagram. The ferrules shall be of plastic insulating material
with permanent black characters on a colour-coded background for numbers and on a white
background for letters, unaffected by oil or water. They shall be so arranged that they can be read
logically from left to right when viewed normally. The system of wire identification shall be such
that wires in the same circuit on opposite sides of a terminal shall have the same reference, and this
system shall be continued through all external cabling. Terminal ferrules (spade, tongue, crimped
connections) shall be provided on each conductor.
571
12.12. Panel earthing
A continuous copper earth bar of not less than 25mm X 6mm cross section shall run the full length
of each panel and shall be securely fixed and bonded electrically to the main frame. The cable
gland-plates and the earth bar shall be provided with suitable brass terminals of not less than 6mm
diameter for connecting the metal cladding or armouring of all incoming and outgoing cables to
the station earthing system.
A second continuous copper earth bar of not less than 25mm X 6mm cross section, electrically
isolated from the steelwork of the panel and metal cladding and armouring of cables, shall be
provided for earthing the signal earth connection of each instrumentation and control device and
the screen(s) of each instrument cable not earthed elsewhere to the station instrumentation earth
plate. The earth bar shall have sufficient brass terminals as specified above for each instrumentation
and control device and the screen of every shielded cable plus 25% spare terminals. In multi-section
panels, each earth bar shall be electrically bonded to the corresponding bars in the adjacent
section(s). Instrumentation and instrument cable screen earthing shall comply with BS 6739: 1986,
Section 10, unless otherwise stated in this clause.
12.13. Panel Heating
Each panel shall have one or more thermostatically-controlled tubular or ribbed panel heaters to
prevent condensation and assist ventilation and which shall be adequate for ambient temperatures
down to 5°C. The heater rating shall not exceed 0.2W/Sq.mm and the surface temperature of any
part which could be contacted accidentally shall not exceed 60°C. Heaters shall be so situated that
no deterioration can be caused to any equipment or wiring in the panel. The heating circuits shall
be switched and fused independently of the instrumentation and control equipment and manually
controlled by an enclosed switch mounted in an accessible position within the panel. Thermostats
shall be mounted remote from the heaters and other sources of heat and shall be fully adjustable
over a range of not less than 0°C to 50°C. Thermostats shall cut out each heater when the internal
temperature of the panel exceeds a preset value; differential thermostats shall be used to maintain
the panel internal temperature at a pre-set value above the external ambient temperature. If the
permanent power supply is not available at the time of installation of the panel and condensation is
detected, a temporary power supply shall be connected to the panel of sufficient rating to operate
the heaters.
12.14. Panel lighting
Each panel shall be adequately illuminated internally, as evenly and as free from dazzle as possible,
by fixed fluorescent lighting controlled from totally-enclosed light switches and by totally-enclosed
door-operated switches positioned so as not to interfere with access. There shall also be one
installed inspection lamp per three meters of panel length or part thereof with adequate flexible
connection cable to reach any point in the panel. The control switch for an inspection lamp shall
form part of the lamp assembly. Lighting circuits shall be fused independently of any
572
instrumentation and control circuit and designed to allow lamps to be replaced safely and shall be
fed from a distribution board and circuit breaker connected on the live side of the main panel ac
supply circuit breaker.
12.15. Panel ventilation
Each panel shall be provided with ventilation fans as required to ensure that equipment within the
panel is maintained within manufacturer’s recommendations, with due regard to the environment
in which the panel will be mounted. Fans shall be controlled by a suitably labeled enclosed switch
mounted internally in an accessible position. Fans shall be mounted with their axes horizontal and
shall be arranged to draw clean air into the panel. Air entries shall have filters which can be renewed
from outside the panel and shall be designed to prevent the entry of rain, spray, injurious fluids,
sand or dust.
12.16. Panel piping and tubing
Panels containing equipment using a supply of compressed air shall have a common air pressure
reducing station with duplicate pressure-reducing valves and filters. The pressure reducing station
shall also include isolating valves upstream and downstream of each filter/reducing-valve set,
pressure-relief valve, pressure indicator and low-pressure alarm unit for the low-pressure header
and a pressure indicator for the high-pressure pipework. The pressure-reducing station components
shall be mounted in a clear space inside the panel, supported on a suitable framework between the
lower horizontal row of instruments and the main low-pressure header. All piping, fittings and
valves downstream of the pressure-reducing station shall be of brass, copper or plastic. PTFE tape
shall not be used downstream of the main filters. The low-pressure header shall be brass and shall
be near the panel floor with drain valves and tundishes piped to a drain. Branch air headers shall be
of brass (15mm diameter minimum) and shall run vertically from the header to the instrument. The
low pressure header and each branch shall have a 6mm minimum, non-ferrous shut-off valve for
each instrument requiring an air supply and a compression coupling for each air-purge connection.
At least 10% spare connections for possible future instruments shall be provided in each panel
section. Any header dismantled before shipment shall have brass unions or flanges at each panel-
section junction. Panel-mounted instruments shall be piped to bulkhead fittings on a gland plate
during assembly at the manufacturer’s works. Piping shall be colour-coded in accordance with
Recommended Practice ISA−RP 7.2 issued by the Instrument Society of America and shall be
segregated from wiring so that any leakage is harmless. Each panel-mounted pressure gauge shall
have a stainless steel flush-mounted shut-off and fine-regulating valve mounted vertically below.
A drip tray shall be provided below each row of gauges. Exhaust and de-pressurizing pipework
shall be routed out of the panel.
12.17. Panel labels
Labels shall be provided for every panel to describe the duty or otherwise identify the panel and its
sections and every instrument, component and item of equipment mounted internally and
573
externally. Where applicable, front-of-panel labels shall be as shown in the Specification drawings.
Each label shall be permanently secured to the surface near the item to which it refers.
Externally-fitted labels shall be of perspex or other approved transparent plastic, with letters and
numbers rear-engraved and filled with black. The rear surface of each perspex label shall be
finished with a coat of paint of the same colour as the panel external finish. Instrument duty labels
fitted externally shall be below the item to which they refer. Embossed tape or similar adhesive
labels will not be approved.
Laminated materials or rear-engraved and filled plastic shall be used for internally-fitted labels,
which shall be white with engraved black letters. Labels conforming to the requirements of the
preceding paragraphs or other approved means shall be provided:
o Labels
 To describe or identify circuits or circuit components
 To identify DC polarity
 To warn or remind about dangerous or potentially-dangerous circumstances
 Wherever elsewhere specified
Unless otherwise specified, all engraving shall be in plain block letters, 4mm high. The
minimum practicable number of different sizes shall be used. Manufacturers’ nameplates
shall not be fitted on panel external surfaces.
12.18. Panel finish
For control and instrument panels, desks and cubicles a hard, smooth, durable finish, free of
blemishes, shall be provided. Before painting, all external welds and any rough areas shall be
smoothed, and all surfaces shall be thoroughly cleaned and free from scale, contaminates corrosion
or grease. If rust-proof or Zintec steel has not been used in the construction, the panel shall be
treated with a passivating agent such as phosphoric acid. All internal surfaces shall have a minimum
of three coats of paint of which the first shall be an approved antirusting priming coat and the final
coat shall be opaque gloss white enamel. All external surfaces shall have not less than five coats of
paint of which the first shall be an approved etch priming coat, and the second and third suitable
undercoats, all of which shall be rubbed smooth when dry before application of the next coat. The
undercoats shall be easily distinguished in shade or colour from the priming and finishing coats.
The two final coats shall be of stove enamel paint, gloss or semi-matt finish, to a colour and finish.
Stoving shall be carried out in accordance with the recommendation of the paint manufacturer. The
overall dry film thickness (DFT) shall be between 85 and 120 microns. Nuts, bolts, washers and
other fixing devices which may have to be removed for transit or maintenance purposes shall be
galvanized or otherwise finished to an approved standard. A 500ml tin of matching touch-up paint
shall be provided and packed with each panel.
13. Electrical Indicators and Integrators
574
Indicators for use with analogue signal-transmission systems shall comply with BS 89:1990 or
equivalent and have an accuracy class index of 1.0. Indicator movements shall be critically damped
(dead-beat). Indicators for use on more than one circuit shall have rotary switches to select the
circuit, with engraved plates to show the circuit selected. Indicators shall have circular scales or
shall be of the vertical edgewise type and shall be designed to avoid parallax error.
Scales shall be clearly marked in SI units and shall comply with BS 3693:1992 or equivalent. All
instruments mounted on one panel or board, or in adjacent groupings, shall have similar styles of
figures and letters. Dials shall be white with black scales and lettering not subject to fading.
The material for scales shall be such that no peeling or discolouration will take place with age under
any environmental conditions. Major scale marks and numerals shall be of the same size and
thickness and shall be separated by not more than twenty-five minor marks. Pointers shall taper to
the width of the scale marks. Integrators shall be of the multi-digit cyclometer type. Integrators
operating in conjunction with an electromagnetic or ultrasonic flow meter shall use the pulse output
from the flow transmitter. Any integrator operating from a device without a pulse output shall have
an integral or separate current-to-pulse converter with sufficient adjustment of the pulse rate to
avoid the use of any multiplying factor except in integer power of 10. Each integrator shall
incorporate an adjustable limiter whereby any input below a pre-set value is inoperative. Unless
otherwise specified, integrators shall have a minimum of eight digits with a decimal point where
applicable.
13.1. Alarm System
Alarms shall be initiated by the opening or closing of volt-free contacts which shall remain
unchanged throughout the periods in which the alarm conditions exit. Alarm circuits shall be
capable of conversion from open-healthy to open-alarm or vice versa by a simple modification after
installation requiring no additional parts or special equipment.
Each alarm shall initiate the operation of both visual and audible devices. The sound intensity of
each audible device shall be suitable for the maximum sound level of its environment.
Audible devices in the same room or area shall have distinguishable sounds and adjustable sound
levels.
14. Matrix Type Alarm Annunciators
The alarm annunciator shall be microprocessor based, modular, split type unit with alarm windows
mounted on the front door and electronic modules inside the panel. The weather protection class
for alarm annunciator shall be IP-54 of IS 13947, Part-I. Each alarm shall initiate a visible and
audible indication of the specified condition. Unless otherwise specified, alarm indicators shall be
grouped together in annunciator units each having at least 20% spare ways. Alarm indicator lamps
(Cluster LED type) shall have transparent screens engraved with appropriate legends as approved
in the Designs and Drawings. The legend area of each indication shall not exceed 40mm high and
75mm wide. When any alarm condition occurs, a condition device common to an alarm annunciator
575
system shall sound and the appropriate indicator shall flash on an off. The flashing rate shall not be
less than 2 Hz and shall not exceed 5 Hz. On pressing an accept pushbutton, the audible device
shall be silenced and the flashing light shall become steady. The alarm indicator shall remain
illuminated until the alarm condition ceases and a reset pushbutton has been operated.
The operation or acceptance of one alarm shall not inhibit the operation of the audible device or
the flashing of the appropriate alarm indicator if a further alarm condition occurs.
At unmanned locations alarms operated on two or more annunciators shall require acceptance at
each annuciator. Alarms shall be accepted automatically and the appropriate audible device
silenced after an adjustable period of 1 to 5 minutes.
An integral ‘test’ pushbutton shall be provided to illuminate each lamp in the appropriate group
and to operate the audible device but shall not cause a spurious alarm condition on any other
annunciator.
Alarm circuitry shall be arranged so that spurious or transient alarm states persisting for less than
0.5 seconds do not initiate any action.
Alarm annunciator / indicator legends or labels shall be arranged with three lines of text as follows:
o Top Line: Location; example: sludge blanket level

o Middle line: parameter; Level
o Bottom line: status. High
15. Push-Buttons and Indicator Lights
Push-buttons in control circuits shall have shrouds, guards or other suitable means for preventing
inadvertent operation. Status-indicator lights shall be of the high-intensity LED type. Indicator
lights shall be of a design which allows easy LED replacement from the front. Indicator lights shall
be easily visible above the ambient light level when viewed from within an included angle of 120
degrees. LEDs shall be chosen to ensure clear discrimination between the energized and de-
energized states and to ensure an average working life of not less than 3000 hours. A ‘lamp test’
push-button shall be provided for each group of indicator lights. The colours of push-buttons and
indicator lights on instrument panels shall be as follows:
o INDICATOR LIGHTS ON INSTRUMENT PANELS

o Start or on (energize) - Green
o Stop or off (de-energize) - Red
o Open valve - Black*
o Close valve - Black*
o Accept - Black
o Lamp test - Black
576
o Reset - Black
o Motor running (energized) - Red
o Motor stopped (de-energized) - Green
o Valve open - Red
o Valve closed - Green
o Urgent alarm - Red
o Non-urgent alarm - Yellow
o Plant healthy or ready for use - White
*Panel-mounted push-buttons for valve operation shall be coloured black, or as per the
approved Design and Drawings, with the duty clearly defined by legend on an associated label.
16. Analogue Signal Transmission
Unless otherwise specified, analogue signal-transmission systems shall be in accordance with BS

EN 60546-1:1993 and shall use a signal of 4mA to 20mA DC. Transmitting devices shall have
integral indicators to monitor the output signal or connections suitable for use with a portable test
meter. Transmitters shall be capable of meeting the requirements laid down in the appropriate part
of IEC 60770-1:1999.
17. Analogue Process Controllers
Analogue controllers shall use solid-state components and shall have outputs containing three terms
with negligible interaction. The controller fascia shall have measured value, set value and output
indication, manual set-value and output controls, auto/manual switch for control mode and remote-
local transfer switch for set-value control. Manual control stations shall have measured value and
set-value indication, local/remote switch and control available lamp indicator. Each controller shall
have the means to restrict its output signal to a predetermined, fully adjustable band so that the
regulating device is not moved to unsafe positions. The adjustment of these safe operating limits
shall be by means of accessible, clearly marked, internal components. A continuously adjustable
proportional band of not less than 5 to 500% shall be provided. Integral and derivative action times
shall be adjustable over ranges which shall not be narrower than 6 seconds to 25 minutes and 0-to
10 minutes respectively. If the integral or derivative action times' adjustments are in steps, the ratio
of successive steps shall not exceed 2. The controls used to set the P, I and D values may be at the
front of the instrument or mounted internally in an accessible position.
Each controller shall be designed so that in the event of failure, it shall be possible to plug a portable
manual station into the controller case and to control the regulating device manually.
Controller design shall ensure automatic procedure-less, bump less transfer whenever the
instrument is switched from "auto" to "manual" or vice versa. Controller action shall be adjustable
from direct to reverse and vice versa by the operation of an internal switch. Analogue process
controllers shall be capable of meeting the requirements laid down in the appropriate part of BS
EN 60546-1:1993.
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578
Section G5.5
SCADA & Online Monitoring System
for STP and LS/ PS
579
Section G5.5: SCADA & Online Monitoring System for STP and LS/ PS
1. General
One of the key requirements forming part of Operation and Maintenance requirement of STPs ,
LS/PS, and I&D is REAL TIME ONLINE MONITORING of various data & details by authorities
& officials in Executing Agency, {NATIONAL/STATE LEVEL AGENCY IF ANY}, CPCB,
SPCB, ULB and Project Engineer.
In order to facilitate this requirement, the concessionaire shall design and implement an SCADA
concept based ONLINE MONITORING SYSTEM for real time monitoring of various parameters
of the STP and LS/ PS including mechanical equipment (pumps, motors, valves, etc.), process
instruments and power network.
The SCADA based REAL TIME ON LINE MONITORING SYSTEM (hereinafter referred to as
RTOLMS) should be such that it has feature as per generic requirements to enable transmission of
real time data of all the monitored parameters over Internet networks, leased and phone lines,
wireless communication etc., or a mix of these as appropriate and as feasible at the respective
site(s). The indicative list of such parameters which are to be logged and monitored / communicated
on line are given in the table below.
Typical parameter and relayed to control monitoring station I&D & distribution chamber
Main pumping
Septage handling system

[LOCATION] STP
station Bio gas generation
Bio gas DG set

Descripti
Parameter
on of
Pumps/Blowers
s
collection well
collection well
equipment's
signal
Sump /
Sump /
Pumps
Other
Date & Real time

Time
Liquid High
Level
Low
580
I&D & distribution chamber
Main pumping

[LOCATION] STP
station
Bio gas generation
Bio gas DG set

Descripti
Parameter
on of
Pumps/Blowers
s
collection well
collection well
equipment's
signal
Sump /
Sump /
Pumps
Other
Liquid flow Inlet flow
measure
ment
Sewage pH, TOC

quality bases
BOD and
COD,
TSS, TP,
TN and
residual
chloride
Pump On, OFF,

status for Trip
individual
pumps
Flow rate in Flow

common rate, head
header /
Outlet
Electrical Voltage,
parameter Current,
for KWH,
individual PF, KVA
pumps &
main
switch
board
581
Main pumping

[LOCATION] STP
station
Bio gas generation
Bio gas DG set

Descripti
Parameter
on of
Pumps/Blowers
s
collection well
collection well
equipment's
signal
Sump /
Sump /
Pumps
Other
No of
operating
personnel
Temperatur
e -
Ambient,
liquid
Bio gas Online

monitoring status for
various
activity
Gas Cum /
generation day,
cumulati
ve gas
generatio
n, gas
quality
Septage Online
handling status for
monitoring various
activity
Septage Cum /
treatment day,
cumulati
ve
septage
582
Main pumping

[LOCATION] STP
station
Bio gas generation
Bio gas DG set

Descripti
Parameter
on of
Pumps/Blowers
s
collection well
collection well
equipment's
signal
Sump /
Sump /
Pumps
Other
received,
quality
DG set
running
hours
Electrical Voltage,
parameter Current,
for KWH,
individual PF, KVA
Bio gas-
based
engine
generator,
DG set
pumps &
main
switch
board
Note: For flow measurement at I&D, the Concessionaire is free adopt any available flow measuring
instruments with compatibility for online monitoring
2. System architecture
The schematic representation of the required RTOLMS architecture to be provided by the Concessionaire
as part of Basic engineering package to meet the KPI requirements as per schedule 1 and 11.
 PLC & SCADA must be of same manufacturer.
583
 There will be one Local Control Station(LCS) at each STP with a common Main Control Station
which will be integrated with all the LCS as per Control System Configuration.
 MCS will have two numbers of SCADA systems as Engineering cum Operator Workstation (EWS)
and Operator Workstation (OWS).
 LCS will have one number of SCADA systems as Engineering cum Operator Workstation (EWS).
 No. of licenses will be same as total nos. of EWS & OWS. Life time license will be in the name of
Executing Agency/ULB and to be provided by SCADA OEM.
 EWS will have run plus development version of SCADA software while OWS will have run version
of SCADA software.
3. Scope of work
The scope of work, as given in Control System Configuration at minimum shall include.
o Supply, installation, testing and commissioning of all necessary Hardware and Software for
RTOLMS System including LAN switches, Modems, UPS, central work station, HMIs, data /
fibre cabling between various sensing devices to the PLCs in the respective STPs, and LS / PS
o Supply, installation, testing and commissioning at STPs,and LS & PS of all necessary isolating
and interface modules and RTUs, potential free auxiliary NO/NC contacts etc., required for
making the existing / new Electrical power system components compatible for monitoring the
voltage, current, PF, kVA, KWh, KVAh, pump ON/OFF status etc., besides interfacing of data
on levels, pressure, flow rate and various other parameters of raw water and treated water.
o Supply, installation, testing and commissioning of al Networking Equipments (Router,
firewall etc.) for the central unit at STP(s).
o Interface / Integration of PLC & RTU of STP, and LS & PS with RTOLMS System.
o Integration of Field Instruments Hardware with RTOLMS System.
o Testing, Erection & Commissioning of supplied system.
4. Features Required in RTOLMS System
RTOLMS system will have many extra features and the proposed system should support multiple
PLC/ RTU Protocol like Modbus, Profibus, DNP (Serial/TCPIP), OPC etc.
4.1. System components
The system shall consist of a modular controller (including control, I/O, and communications
functions) and software modules that facilitate open systems connections.
584
The system shall include a full complement of modular supporting equipment (including mounting
racks, power supplies, termination strips, equipment enclosures, prefabricated cables, furniture,
etc.), all of which shall be designed to simplify construction.
4.2. Open Communications
The control system shall be open to enable easy integration with OPC (OLE for Process Control)
[where OLE stands for Object Linking and Embedding (OLE)] server so as to collect the data from
the remote housing station.
4.3. Reliability and redundancy
The system must be designed for maximum reliability and minimal downtime and work
satisfactorily under harsh and dusty ambient conditions. This should be achieved through a fault-
tolerant design with minimal common cause failures and state-of-the-art redundancy schemes. The
main system should offer 100 % redundancy for both hardware and software. The offered system
shall offer highest possible MTBF within the service period of 15 + years.
4.4. Hardware Details

This section contains a detailed configuration description of automation system. The building sub-
systems are as per the Scope of Work:
 SCADA cum Communication Server

 User Interface subsystem like WS
 IP Camera & IP phones
 Local Area Network subsystem like LAN switch, Router, Firewall
 12 C Single Mode Fibre cable
Each subsystem is built from hardware common components. All subsystems and hardware
components are described below:
o Subsystem Description
This section lists and describes the subsystems (associated hardware components) at each location.
 SCADA CUM COMMUNICATION SERVER, WEB SERVER, ISR SERVER
Qty Hardware Component Remarks

1 RTOLMS SCADA cum o The interfaces for each server are connected to Ethernet
Communication Server networks to collect data from field.
1 WEB server o Interface with Internet to remote client
585
1 ISR server o Databases server with Oracle/SQL for Alarm and MIS Report
 USER INTERFACE SUBSYSTEM
Hardware
Qty Remarks
Component
As per System Workstation o The console is provided with TFT Monitor
Configuration diagram and Console o The interface is connected to the Ethernet
system requirement networks.
1 Remote access o LAPTOP connected through a serial link and a
terminal modem.
As per System HMI o The interface is connected to the Ethernet
Configuration diagram (10”Minimum) networks.
and system requirement
As per System Large Video Screen o The interface is connected to the Ethernet
Configuration diagram networks.
and system requirement
 LOCAL AREA NETWORK SUBSYSTEM

As per LAN Switch Ethernet switch 14 ports (10/100 Base TX) + 2 Fibre Port
System Remote Location LAN Ethernet switch 14 ports (10/100 Base TX) + 2 Fibre Port
Requirement switch
Router Port 2 LAN+2 WAN, all are 10/100 with 2 V.35
Firewall 4LAN+2 WAN, all Wan are 10/100Mbps and LAN are
10/100/1000 Mbps
Lot 12C Single armored cable For Connectivity
Mode Fibre
4.5. Peripheral Subsystem
 PRINTERS

1 no. Laser Printer(A3Colour), A4 Each laser printer is connected to Ethernet network.
each B/W
586
 UPS

2 UPS of appropriate kVA rating for Main The UPS shall be with two hours battery
Control Room autonomy.
2 no. UPS of appropriate kVA rating for STP, The UPS shall be with 2 hours battery
each autonomy
1 no. UPS of appropriate kVA rating for MPS, The UPS shall be with 2 hours battery
each LS & PS autonomy
IP Camera
Qty Hardware Remarks

Component
As per system IP Camera  Each Camera is connected to Ethernet network for
requirement & system Remote location surveillance
configuration
diagram
Video Projection System
Qty Hardware Remarks

Component
1 no. each (1x2 Rear Projection one  Each VPS is connected to Ethernet network.
matrix) at STPs and cube with controller
Main Control Room
4.6. Hardware Components Description
This section describes the common hardware components.
 Communication cum SCADA Server, Web Server, ISR Server* Characteristics *
Intel® Xeon® Quad-Core Processor E5606 2.13 GHz, 8MB L3 Cache 1

Integrated Two Broadcom dual-port Gigabit Ethernet with TOE enabled 1
8GB Memory (4x2GB), 1333MHz, DDR3 RAM 1
2nd Intel® Xeon® Quad-Core Processor E5606 2.13 GHz, 8MB L3 Cache 1
587
300GB 15K RPM,6Gbps SAS 3.5 Hot Plug Hard Drive " With RAID5 3
DVD+/-RW ROM, SATA, Internal for Ms 2008 R2 1
High Output Power Supply, Redundant, 460W 1
Power Cord, GType, 230V (Nepal, Sri Lanka, India) 2
2U Cable Management Arm 1
2U Sliding Rail 1
Windows Server 1
* The system (hardware, software, accessories, etc.) being provided during installation would be
of latest configuration.
 Workstation Console Monitor*
Motherboard Intel® Xeon® Dual-Core Processor W3503 (2.40 GHz, 4 MB cache, 1066 MHz
memory)
Video Card ATI FirePro 2270 (512 MB)
RAM Memory 4GB (2x2GB) DDR3 SDRAM Memory, 21333MHz, ECC 1
HDD 1 TB SATA (7200 RPM) HDD
Input Power Supply 220 to 240 VAC (+/- 10%), 50 Hz (+/- 2 Hz)
Power Cord Indian Style
CD Drive 16X DVD + /-RW Combo Drive
Keyboard USB Entry Keyboard
Mouse USB Optical Scroll Mouse (2 buttons) with Mouse Mat
LAN (Ethernet port) Dual Broadcom RJ45 10/100/1000 BASE on board Ethernet NIC
I/O Cards One serial RS-232 port, 4 USB port and one parallel portVGA Port,DVI Port,
Line In/Out &microphone port, Expansion card slot, Network port
Indicator & Switch Power on/off x 1, HDD x 1. Power on/off x 1, System reset x 1
*The system (hardware, software, accessories, etc.) being provided during installation would be
of latest configuration
Remote Access Terminal (1no.)
Laptop Characteristics *
Processor 2nd generation Intel® Core™ i5/7 processor (2.30 GHz, 1333, 3M
cache)
Operating System Genuine Windows® 7 Professional SP1 32bit (English) for India
Display 14.0" HD WLED Anti-Glare (1366x768)
Memory2 2GB2 DDR3 SDRAM at 1333MHz
Hard Drive 320GB 5400RPM SATA Hard Drive
Video Card Intel® HD Graphics/ Intel® HD Graphics 3000( It depends on
processor selected)
*The system (hardware, software, accessories, etc.) being provided during installation would be of
latest configuration.
588
HMI Characteristics *
Size Minimum 10 “ (Touch Screen)
Display 800X480Pixel LCD display with back-littodisplay

Interface/Port Inbuilt Ethernet,USB miniportstype A for report generation
datalodging,485Port embedded
Luminance 450cd/m2
Real Time Clock Required
Front Panel IP-65
Other Facility to connect printer
Serial & parallel printing option
65”Interactive 4k Panel (LVS)Characteristics *
Display Technology Type Backlit LED (IPS Panel)
Panel Size 65”
Brightness (Typical/Minimum) 330cd/m2 or better
Contrast Ratio (Typical) 1,200:1 or better
4K Ultra-HD (3840 x
Native Resolution
2160)
Display Viewing Angle (H/V) 178/178 degree
Aspect Ratio 16:09
Response Time (MS) 8ms (Typ) or better
Refresh Rate (Hz) 60Hz
Estimated Life Time (Typical) 30,000 hours (Min)
Display Color (Bit) 1.06 billion (10-bit)
Orientation Landscape
Touch Technology Infrared Touch
Interactiviy Writing 10 Points

Touch Points
Touch 20 Points
589
±2mm (Over 90% area) or
Accuracy
better
Response Time <15ms or better
Touch Resolution 32,767 x 32,767 or better
4mm Thick Toughened

Surface Protection Glass (Level 7H on Mohs
Scale of Mineral Hardness)
Single-Touch 6mm and

Minimum Touch Object
Multi-Touch 8mm
Finger, Stylus, Glove,

Touch Tools
Opaque Objects
Use palm/hand back to

erase/ Slide up from
bottom to call out Touch
Menu//Two fingers to call
Gestures Supported out floating toolbar. /Under
PC:20 point touch, 10
point writing. Under
Android, 10 point touch. 5
point writing
Windows® (Windows 7
and above: Driver Free),
Mac® (10.10 and above),
Android™
OS Compatibility (2.2/2.3/4.0/4.1/4.2 (Kernel
v3.5 and above - Driver
Free), Chrome (v39 and
above), Linux (Kernal v3.5
and above)
System Version Android™ v6.0 or latest
RK3399, Dual-Core
ARM® Cortex® A72 and
CPU
Quad Core ARM®
Operating Cortex® A53
System
GPU Mali™ T860
RAM 4GB DDR3
Internal Storage 16GB (eMMC Flash)
590
HDMI v2 (x1), HDMI v1.4
Display (x2), DisplayPort (x1),
Input VGA-In (x1)
Audio-In (3.5mm) (x1),

Audio
AV-In (x1)
Display HDMI-Out (1080P) (x1)

Out Audio-Out (3.5mm) (x1),
Audio
Coaxial-Out (RCA) (x1)
Connectivy
Internet LAN (RJ45) (x1)
Control RS232 (x1)
USB 2.0 (x2), USB 3.0

Front
(x1)
USB 2.0 (x1), USB 3.0

USB
Side (x1), USB Type B (x2)(For
Touch Port)
Bottom USB 2.0 (x1)
Expansion Novo Pro Android Module (Slot 1) Built-in (120pin)

Modules
(OPS) Windows PC Module (Slot 2) Optional (120pin)
Audio Internal Speakers 12W (x2) (Stereo)
Power Supply (Internal) AC 100-240V, 50/60Hz
Power Consumption 300W or less
Standby Mode <0.5W (Standby)
Temperature 0°C - 40°C (32°F - 104°F)

Operating
Humidity 10% - 90%
Environmental -20°C - 60°C (-4°F -

Temperature
Conditios Storage 140°F)
Humidity 10% - 90%
Altitude Below 5,000m (16,400ft)
Dimension
Product 1,521 x 915 x 98 mm
Physical (L x H x D)
Characteristics
Weight Net 47kg or less
591
4 - M8 × 25mm, 800 x
VESA Mounting (FPMPMI)
400mm (31.5" x 15.7")
Aluminium (Front Frame),

Construction/Materials
Iron (Rear Cover)
AC Power Cord, VGA

Cable, USB Cable, Audio
Cable, Stylus (x3), Wall
Accessoris Standard
Mount Kit, Remote
Control, Documentation
Kit
1. MMirroring for iOS Airplay®, Android™ Miracast, Windows®

PC, Apple® mac OS™, Google Chromebook™ –OS independent
2. Wireless facility with 802.11n/ac dual-band 2.4/5GHz support
Built-in 3. RRemote manager with IT management software with automatic

Features discovery and Configuration
4. Voting and polling functions
5. Connect up to 64 users simultaneously, and allow 4 people to

present on one display
 The OEM should have service centers spread all over India.
*The system (hardware, software, accessories, etc.) being provided during installation would be of latest
configuration.
 LAN Switch*
Specification Managed Industrial Ethernet switch

IEEE 802.3 for 100BaseT(X) and 10BaseT
Ethernet Standards IEEE 802.3u for 100BaseFX
IEEE 802.3x for
Flow Control
FCC Part 15, CISPR (EN55022) class A, Shock- IEC60068-2-27,
Design Standard Vibration-IEC60068-2-6, EN61000-4-2 (ESD), EN61000-4-3
(RS), EN61000-4-4 (EFT), EN61000-4-5 (Surge),
EN61000-4-6 (CS), EN61000-4-8, EN61000-4-11 standards
Input Voltage 9.6-60 VDC
Operating temperature: 0 to 60°C
592
Specification Managed Industrial Ethernet switch
Ambient Relative 5% to 95% Non-condensing
Humidity:
Overload Current Present
Protection
Mounting DIN Rail Mounting
No. of Ports 12 Nos. (10 CU + 2 FO)
Interface
Ethernet ports 10 no. RJ45 Ports with 10/100BaseT(X) auto negotiation speed,
Full/Half duplex mode, and auto MDI/MDI-X connection
Fiber Port Two 10/ 100BaseFX port SC Type Single-Mode, 1310 nm
Supports Ring, and Self-Healing
The system (hardware, software, accessories, etc.) being provided during installation would be of
latest configuration.Color& Black & white Laser Printer Characteristics *
Print speed Up to 12 & 8 ppm

Print quality Up to 600x600 dpi with HP ImageREt 3600
(A3 (Colour)A4 (B/W) Size,
26/32 sec
ready)
Exact speed varies depending on the system configuration,
Print speed footnote
software application, driver and document complexity.
Memory, standard 128 MB, expandable to 384 MB
Processor speed 600 MHz
Duty cycle (monthly, A4) Up to 30000 pages
Hi-Speed USB 2.0 port; built-in Fast Ethernet 10/100Base-
Connectivity, standard
TX
Print technology In-line colour / B/W laser printing technology
Print languages HP PCL 6, HP PCL 5c, HP Postscript level 3 emulation
Paper trays, standard 2
Paper handling input, standard 150-sheet input tray
Paper handling output, standard 150-sheet face-down output bin
Input voltage 115 to 127 VAC (+/- 10%), 60 Hz (+/- 2 Hz),
Power
12 A; 220 to 240 VAC (+/- 10%), 50 Hz (+/- 2 Hz), 6 A
445 watts maximum (active), 18 watts maximum (ready),
Power consumption
6.7 watts maximum (sleep), 0.48 watts maximum (off)
Tray 1: A3/A4, A5, A6, B5 (JIS), 10 x 15 cm, 16K,
envelopes (ISO DL, ISO C5, ISO B5), post cards (Standard
Media sizes supported #10, JIS Single, JIS Double); Tray 2 : A3/A4, A5, A6, B5
(JIS), 10 x 15 cm, 16K, envelopes (ISO DL, ISO C5, ISO
B5), post cards (JIS Single, JIS Double)
Tray 1: 76 x 127 to 216 x 356 mm; Tray 2 : 100 x 148 to
Media sizes, custom
216 x 356 mm
593
Tray 1: 60 to 176 g/m² (up to 220 g/m² with HP laser glossy
photo papers); tray 2, optional tray 3: 60 to 163 g/m² (up to
Media weight, supported
176 g/m² with postcards, up to 220 g/m² with HP laser
glossy photo papers)
Recommended operating 15 to 27° C
Operating humidity range 20 to 70% RH
* The system (hardware, software, accessories, etc.) being provided during installation would be
of latest configuration.
 UPS*
Micro processor based IGBT, High Frequency Switching

Technology
Sinusoidal multiple PWM
Rating As per system requirement
Input 230 V AC, +10%, -15%
Input Voltage Range 100 ~ 300V AC (fullload)
Current Harmonic / Distortion <5%(full load)
Power Factor >0.99(fullload)
Input Frequency 40 ~ 70Hz
Output 230 V AC
Voltage Harmonic Distortion ≤ 2% (linearload)
Voltage Regulation ±1%(static); ± 2% (typical)
Output Frequency 50or60 ± 0.05Hz
106 ~ 110%:10 minutes;
Overload Capability
111~ 125%:5minutes;126 ~150%:30seconds
Electrical Connection Terminal block
CrestFactor 3:1
Battery Sealed Maintenance Free Batteries,
Backup Hours 120 Minutes
LED :- AC input, Battery,Bypass,Fault

LCD(Multi-Language) :-
Display Input/Output/Bypass(voltage,frequency),Loadingandbatteryl
evel,RemainingruntimeAbnormalmessageandintelligentself
diagnosis
Standard :- RS232 x1,SNMPslotx1, Smart slot x1,Parallel
portx1
Management Peripherals (SNMP Slot) :-
SNMPcard,Modbuscard, RelayI/Ocontrolcard, Enviro Probe,
Interface
SNMP hub
Management Peripherals (Smart Slot) :_ MiniSNMPcard,
MiniModBuscard,MinirelayI/Ocontrolcard,USB card,TVSS
card
Efficiency (Online Mode) :- 92 % (Fullload)
Overall Efficiency (Eco Mode) :- 96 % (Fullload)
Temperature: - 0 to 40 Deg C
594
Relative Humidity: - 0 ~ 95%(non-condensing)
AudibleNoise :- 54d BA (atone meter)
Parallel Redundnacy (1+1) at LCS, MCS &STP. Non
Redundant for IPS & MPS
Common Battery Installation :- Feasible
Conformance Safety :_ CE,TUV, EN62040-1-1
EMC :- CISPR22 Class A, EN50091-2, IEC 61000
 Router *
Memory RISC @ 533 MHz

Flash Memory:256M Bytes
SDRAM: 256M Bytes
Interface 2 x 10/100/1000 Mbps Ethernet Port
2 Serial Ports (V.35)
2 X 10/100 Mbps WAN Interface
1 Console port
1 Auxiliary port
Performance
Throughput 300 Kpps (64-byte packets)
Routing table size 30000 entries
Network Management IMC - Intelligent Management Center; command-line interface;
Web browser; SNMP Manager; Telnet; RMON1; FTP; IEEE 802.3
Ethernet MIB
Operating Temperature 0° to 40° C (32° to 104° F) (Relative Humidity: 5% to 90% non-
condensing)
Non-Operating -40° to 70° C (Relative Humidity: 5% to 90% non-condensing)
Temperature
Power 100-120/200-240 VAC
 IP Camera
Camera
Sensor 1/2.7” HD progressive scan CMOS
Lens C/CS mount lens (lens not included)
Auto Iris Type DC drive
595
Illumination (low light sensitvity) • Color: 0.2 lux at F1.2
• B/W: 0.05 lux at F1.2
Synchronization Internal
White Balance ATW/AWB (range: 3200 to 10000°K)
Dynamic Range • Color: 100 dB

• B/W: 110 dB
Auto Electronic Shutter 1/30 to 1/25000 sec.
Electronic Shutter Auto
S/N Ratio 50 dB (Gamma, Aperture, AGC OFF; DNR ON)
ICR Control Auto (light sensor control) or DI control
DNR Built-in DNR
WDR Level 1-8/Off
AGC control 2X, 4X, 8X, 16X, 32X, 64X
Flickerless Control Indoor/Outdoor mode
Black Level Control High/Medium/Low
Auto Exposure Level ±5
Image Rotation Flip, Mirror, and 180° rotation
Image Setting Manual tuning with saturation, sharpness, and contrast
• Video
Video Compression H.264 (ISO/IEC 14496-10) or MJPEG
Video Outputs Ethernet
Up to 3 video streams (2 x H.264 and 1 x MJPEG)
• Stream 1: H.264, 1280 x 800 resolution (max.)
Video Streams
• Stream 2: H.264, 720 x 480 resolution (max.)
• Stream 3: MJPEG, 720 x 480 resolution (max.)
Note Streams 2 and 3 must be at the same resolution
Video Resolution and FPS (frames
Not less than 20 FPS in NTSC or PAL
per second)
• Network
(ONVIF compliant) ,TCP, UDP, HTTP, SMTP, FTP,
Telnet, NTP, DNS, DHCP, UPnP, RTP, RTSP, ICMP,
Protocols
IGMPv3, QoS, SNMPv1/v2c/v3, DDNS, Modbus/TCP,
802.1X, SSH/SSL
Ethernet 1 10/100BaseT(X) Ethernet port, RJ45 connector
• Serial Interface
RS-485 1 half-duplex RS-485
• GPIO
1, max. 8 mA
Digital Input • High: +13 V to +30 V
• Low: -30 V to +3 V
Relay Output 1, max. 24 VDC @ 1A
• LED Indicators
STAT Indicates if the system is booted properly or not
Network 10 Mbps or 100 Mbps
596
Power Power on/off
• Local Storage
SD Socket Standard SD socket (SDHC)
• Power Requirements
• Redundant power inputs

Input
• 12/24 VDC, 24 VAC, or Power-over-Ethernet (IEEE
802.3af)
• Physical Characteristics
Camera Body Housing Metal, IP30 protection
Installation Wall mounting, pole mounting, corner mounting
Optional external housing and mounting accessories may
Note
be required.
• Security
Password User level password protection
Filtering By IP address
Authentication 802.1X
Encryption HTTPS, SSH
• Alarms
Camera tamper, virtual fence, alert zone, missing object,
Intelligent Video
unattended object
Note IVA functions are optional except for camera tamper.
Video Motion Detection 3 independently configurable motion areas

Scheduling Daily repeat timing schedule
Imaging JPEG snapshots for pre/trigger/post alarm images
Video Recording Event recording and stored in the SD card
Automatic transfer of stored images via email or FTP as
Email/FTP Messaging
event-triggered actions
Custom Alarms HTTP event servers for setting customized alarm actions
Pre-alarm Buffer 24 MB video buffer for JPEG snapshot images
• Environmental Limits
Standard Models: 0 to 60°C (32 to 140°F)
Operating Temperature
Wide Temp. Models: -40 to 75°C (-40 to 167°F)
Storage Temperature -40 to 85°C (-40 to 185°F)
Ambient Relative Humidity 5 to 95% (non-condensing)
• Standards and Certifications
Safety UL 60950-1
UL/cUL Class I Division 2 Groups A/B/C/D (Pending),
Hazardous Location
ATEX Zone 2 Ex nCnAnL IIC T4 (Pending)
EMI FCC Part 15, CISPR (EN 55022) class A
EN 61000-4-2 (ESD), Level 3,
EN 61000-4-3 (RS), Level 3,
EN 61000-4-4 (EFT), Level 3,
EN 61000-4-5 (Surge), Level 3,
EN 61000-4-6 (CS), Level 3,
EN 61000-4-8,
597
EN 61000-4-11
Traffic Control NEMA TS2
Rail Traffic EN 50121-4
Shock IEC 60068-2-27
Freefall IEC 60068-2-32
Vibration IEC 60068-2-6
latest configuration
 Video Projection System 2 X 1 (1 No)
Cube & Controller should be from the same manufacturer

Resolution 1920x 1080
Light Source type Nichia Laser light source, Individual cube should be equipped
with at least 3 laser banks and each laser bank should have
minimum 8 diodes
Light Source Redundancy System should be able to Illuminate all the laser banks at the
same time , system should not be Blank( No image ) screen
due to failure of any diode in any laser bank
Brightness Minimum 2200 lumens
Control IP Based Control to be provided
Remote IR Based Remote Control shall be provided
Contrast Ratio Min 1800:1 or better
Screen to Screen Gap ≤ 0.2 mm
Cooling Inside cube should be by means of a heat pipe only .Pump
based cooling involving hazardous liquids is not acceptable
Source redundancy System should be able to switch to HDMI input if primary DVI
input is not available and system should also automatically
switch back to primary DVI input from HDMI input as soon
as the primary DVI input is available again.
Cube depth including screen should be less than or equal to 460 mm
module
Maintenance Access Rear.
Cube Size not be less or more than 67" diagonal size.
Video Wall Controller
Controller Controller to Control video wall in a Matrix (2x1) output-input

along with softwares
Chassis 19” Rack mount
Processor Single Quad Core Intel® Core™ i7 Quad Core 3.4 GHz
processor) or better and supports 64-bit Operating System
Windows 7 with RAM capacity of 16 GB or more with HDD
500 GB or more
Net Working Dual Port Gigabit Ethernet.
Power Supply 1+1(Redundant Hot Swappable).
Cooling Advanced proven cooling mechanism
598
Input/Out Put Support DVI/HDMI/USB/ LAN/ VGA/SATA port.
Accessories DVD +RW, Keyboard and mouse
Voltage: 100-240V @ 50/60 Hz
Redundancy Support Power Supply, HDD, LAN port & Controller
Scalability Display multiple source windows in any size, anywhere on the
wall
Control Functions Brightness /contrast / saturation/ Hue/ Filtering/ Crop / rotate
Formats DVI/RGB/Component and NTSC/PAL/SECAM
Operating temperature 10°C to 40°C , 80 % humidity
Video Wall Display multiple sources anywhere on display up to any size

ManagementDisplay and
Scaling:
Input Management All input sources can be displayed on the video wall in freely
resizable and movable windows and should save and load
desktop layouts from Local or remote machines.
Layout management: It should support all Layouts from Video, RGB, DVI, Internet
Explorer, Desktop and Remote Desktop Application and
Multiple view of portions or regions of Desktop, Multiple
Application can view from single desktop.
Other Features Remote Control over LAN, Remote management, alarm

management& multiple concurrent clients
Cable Management: Cube Health Monitoring, Pop-Up Alert Service and graphical
User Interface.
It should be able to provide an error message in three sections

a) Problem area b) Error Module Location c) Error Module
image
Should be able to control & monitor individual cube, multiple
cubes and multiple video walls
Provide video wall status including Source, light source,
temperature, fan and power information
Should provide a virtual remote on the screen to control the

video wall
Other
Input sources can be scheduled in " daily", "periodically" or
"sequentially" mode per user convenience
System should have a quick monitor area to access critical

functions of the video wall
User should be able to add or delete critical functions from
quick monitor area.
Automatically launch alerts, warnings, error popup windows

in case there is an error in the system
*The system (hardware, software, accessories, etc.) being provided during installation would be of latest
configuration
599
 12C Single Mode Fibre Cable*
Configuration Multitube double sheath armoured cable

Nos. of Core 12
Maximum Tensile Loading 1361 x 1021
Installation 2700N
Long Term Installed 900N
Operating Temperature -30°C to +60°C
Normal Dia 14.8 mm
Nominal weight 200 KG/KM
Mode Single Mode
Single mode Fiber: (G.652.B)
4.7. Server Panel
The equipment can be of any Standard make which can comply with the following standards:
Type SERVER RACK 42U/600W/1000D

Specification Captive Front Panel Hardware, Pkt of 20
Castors (Plain)
Server Rack, 19"/42U
consisting of High quality extruded Aluminium vertical profiles 4 Nos.
Top and Bottom steel end
frames with bottom Panel having gland plate for cable entry, Top cover
with FHU provision, Side
Panels with latches and venting slots at bottom 1/3 area and 2 pairs of 19"
Mounting Angles
Dimension: 2150 x 600W x 1000D Powder Coated BLACK
Front CRCA steel single door with Perforation
Rear CRCA steel single door with Perforation
Component Shelf, Universal, 19"W/575mmD, Load cc 50 kg.
Top Mounting, Fan Housing Unit with 4 fans 230 V / 90CFM
Rotary Keyboard Tray with slides
Castors (with brake)
Earth Continuity straps (kit)
1.8 PLC System Details

Description Specification
600
PLC Type HOT Redundant PLC
Data Exchange through high speed link of 1 Gbps
Operational Voltage 24V DC
Specification Local indication using LED
CPU 16-bit Dual core processor
Programming Memory & Data 32 MB ON board memory

Memory
Clock Real time clock (RTC)
Communication Serial (1 - RS 232, 1 - RS232/RS485)
(GSM, GPRS, Data call, Satellite, Radio
modem, serial, Ethernet)
Communication port 1 nos RS 232/RS 485
1 Nos 10/100 base Ethernet port,
1 Nos USB Port
Ethernet Services FTP Server, SNMP, DHCP Client, IEC
VAR Access, Modbus TCP Server/Client
Web Services Web Server
Operating temperature -10 to 55 deg C.
Storage temperature -40 to 70 deg C
Humidity 5- 95 % Non-condensing
Vibration 3 gn (vibration frequency: 8.4...150 Hz) on
panel mounting
Shock Resistance 15gn for 11 ms
Operating Altitude 0 – 2000m
The system (hardware, software, accessories, etc.) being provided during installation would be of
PLC Input-Output Details
1 Input/outputs
601
2 Digital Input 16
3 Operational Voltage 24V DC
4 Specification Local indication using LED
5 Analog Input ranges 0-10VDC, 0-5VDC, 4-20mA, 0-20 mA
6 Resolution 16 bits
7 Digital Output 16
8 Relay type Relay/transistor Output
9 Operational Voltage 24V DC
10 Specification Local indication using LED
11 CPU 16-bit Dual core processor
12 Programming Memory & Data Minimum 1 MB ON board memory

Memory
13 Clock Real time clock (RTC)
14 Analog to digital converter 12/16-bit Resolution
15 Communication port Dual LAN Ports 10/100/1000 MB Ethernet port
1 nos Serial Port
16 Operating temperature -10 to 55 deg C.
17 Storage temperature -40 to 70 deg C
18 Humidity 5- 95 % Non-condensing
19 Vibration 3 gn (vibration frequency: 8.4...150 Hz) on
panel mounting
20 Shock Resistance 15gn for 11 ms
21 Operating Altitude 0 – 2000m
• PLC System Should Support for communications protocols, including PROFINET, Modbus
TCP/IP
602
• Advance cyber security with Achilles Level 2 certification or equivale
Specification of PLC / Control System.

Powerful Integrated Controller
The controller shall consist of a family of intelligent integrated modules, with each performing a
dedicated function. It shall have an integrated redundant interface for the I/O modules as well as
redundant interface for the Human machine interface.
Controller shall have the reliability factor with high MTBF within the service period of 15 + years
As per DIN 40041, reliability is understood to be the "the property of an entity to fulfill its reliability
requirements during or after a given time span under given application conditions", therefore
concessionaire is required to assure the airconditioned environment of PLC system as stipulated in
Annexure provided as part of Scope of Works.as minimum requirement.
Modular Architecture
The modular approach shall enable a very small system to be installed with expansion to a very
large system without changing the basic hardware or disrupting the architecture. A minimum of
the following module types must be available: control modules, I/O modules, communications
modules, computer modules, and power supply modules.
Controller Packaging
For installation flexibility and high reliability, controller hardware must be designed to withstand
harsh conditions within industrial environments, such as heat, humidity, shock, vibration, and
electrical surge and discharge.
Module Hardware
Module hardware must meet the following requirements:
 The modules shall be identical in appearance.
 All the module shall be housed in a powder coated metal case rack to prevent physical damage
from handling or dust.
 All control and I/O modules shall be rated for operation within the following ranges: 0-50 Deg
C and 5-95% relative humidity, non-condensing.
 I/O and power modules shall have circuitry to protect the system from electrical surge and
discharge.
The modules shall comply with the following specifications:

International Electro-technical Commission (IEC)
 IEC 60751 (1983-01) Industrial platinum resistance thermometer sensors

 IEC 61000-4-2 (2001-04) Electromagnetic compatibility (EMC)- Part 4-2
 IEC 61000-4-3 (2002-03) Electromagnetic compatibility (EMC) - Part 4-3
 IEC 61000-4-4 (1995-01) Electromagnetic compatibility (EMC) - Part 4
 IEC 61158 (2000-08): Field-bus standard for use in industrial control systems - Part 2:
 IEC 61131-3 (1993-03) for Programmable controllers - Part 3
603
The modules shall comply with the following shock and vibration standards:
 Vibration: IEC 68-2-6, Fc: 10-50 Hz, 2g
Module Racks
The modules shall be grouped together in racks to form the control system. The racks shall
provide the communications mechanism to fully integrate the modules and facilitate
intercommunications between racks. A rack should hold approximately ten individual modules,
with each slot identical and able to accept any module. Modules should be connected to the
backplane using high quality, gold-plated, industry-grade pin connectors.
It shall be possible to remove and reinsert the modules under power with no damage to the rack
or modules and without removing any external wiring or cables. The rack and modules shall
provide a physical keying mechanism to prevent incorrect module insertion during system
operation.
To simplify installation and maintenance, the module racks and modules shall be designed for
front access only. All user functions, including diagnostics, field wiring, cable connections,
switches and status indications, shall be available from the front of the rack.
4.8. Power Supply
Redundant power supplies shall be available for card rack mounting to form as an integral part of
the system. The module rack must provide two individual power supply buses that to be driven by
two independent power sources for high availability placed in the rack in current sharing mode.
Each module shall be capable of using power from any of the two buses.
4.9. Enclosures
The racks shall be mounted in an industrial enclosure with a front & rear -access design, with all
frequently accessed items (such as modules, connectors, status indicators, switches, and
termination assemblies) located in the front of the enclosure. For maximum flexibility, the
enclosures shall be modular, with the ability to be stacked, joined side to side, or joined back to
back. To provide the degree of environmental security required, enclosures shall be available in
sealed and vented versions.
Enclosure shall be i) for Indoor IP 44 and ii) for Outdoor IP 65
Control Module
A control module shall provide process control functions. The control module should be used with
dedicated I/O modules to read and control field signals. The module shall also be capable of
operation independent of I/O modules, “supervising” operation of other control modules. In
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addition, the control module shall be capable of executing on a 5 millisecond resolution input-to-
output when required by the application.
A. Hardware
The control module shall consist of a single-slot module with a dedicated microprocessor. Memory
should be battery-backed RAM so that the module retains its configuration and state information to
optionally and automatically restart after a power failure without requiring its database to be
downloaded. The minimum memory required is Server Grade PC, RAM min. 16 GB, HDD 500GB
SSD+500GB Sata, HDMI port: 2 nos, RAID 1 PC
B. Software
The control system must support a full complement of process control functions. It shall be possible
to define these functions using a mix of function blocks, ladder logic diagrams, sequential function
charts, and textual programming. Each of the four languages and their interaction within a
configuration shall be based on the IEC 61131-3 standard. The languages shall be completely
interchangeable and interactive, with a single control module’s database capable of including any
combination of the four languages.
4.10. Input / Output Devices
Input/output Modules shall be intelligent I/O modules. Each module should be able to communicate
with the CPU in a dedicated fashion without requirement of any additional interfacing hardware so
as to reduce the common cause of the Failure. Each module should have its own microprocessor to
execute its input/output function, maintain its configured data, and perform module diagnostics.
All process I/O shall be electrically isolated from both computer common and communications
common. Isolation shall meet be min 1500 VAC requirements. Modules shall automatically
determine their physical address and report this information to the controller. No range jumpers or
user- configurable physical address jumpers should be necessary.
All configurable data shall be set via software, with no hardware jumpers used. Configurable data
should include channel tag.
All the I/O modules shall have max 8 channels for the Analog and 16 channels for the Digital
modules. Special modules like Counter inputs shall monitor dry contact pulses with an input
resolution of one HZ minimum. More numbers per channel may be accepted if the overall reliability
factor of MTBF within the service period of 15 + years is achieved.
4.11. Field Termination for I/O Modules
Each I/O module’s field signals shall be wired into the system such that an I/O module can be
removed at any time without disturbing the field wiring.
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The field wiring should be separate from the I/O module(s). The extension from the module(s) shall
be accomplished via a marshalled I/O cable assembly. This assembly should be a multi-conductor
cable that attaches to the module rack (and the back of the I/O module) on one end and a finished
termination end.
The marshalled termination assemblies shall be DIN rail-mounted PCB-based fixtures that include
terminal blocks and two receptacles for accepting the interconnect cable plug. These receptacles
must be female to eliminate the possibility of power from the terminal block being exposed on pins.
4.12. System Communications
The communication networks in the system shall provide redundant, high-speed, secure
controller information exchange via Ethernet TCP/IP. Communication between individual
modules shall be via redundant, local, independent buses that allow complete integration
of the family of modules.
Module Communication Bus
All the communication to the I/Os in the PLC shall use a deterministic. This protocol must be
compliant to IEC61158, and open. It shall be possible to connect a minimum of 100 nodes on a
single network
The bus must be redundant. Minimum data transmission rate is 10 Mbps.
Communication on the expanded network shall be accomplished in a manner identical to that of

local communication bus. The extension shall be transparent to the user, and no extra software
configuration effort shall be required.
Configuration Software
The configuration software shall be portable. It shall run on a personal computer of the most current
Windows based operating system.
The software shall execute in the off-line mode when the computer is not attached to any controller
hardware, allowing controller databases to be created, edited, and documented. When the computer
is attached to the controller hardware via the networked or direct-connected PCs, the networked
workstations, or by running in the industrial computer module, an on-line mode of operation shall
be available to allow use of all off-line functions plus on-line troubleshooting tools. This software
shall be able to be used to configure continuous, batch, and safety protection control strategy
configurations from a single user console.
IEC 61131-3
The configuration software shall allow controller databases to be created using the following
standard languages defined by the specification IEC 61131-3: function blocks, ladder logic,
sequential function charts, and structured text.
Graphical Configuration and Documentation
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Controller configuration should provide graphical configuration methods, with functions entered
into a database using a point and click object-oriented routine. The resulting database should be its
own documentation because of the graphical appearance. Furthermore, the graphical database must
be transferable directly to the controller as it exists, including all graphical information, with no
compile routine necessary before transferring the database to the controller. The graphically
configured database shall be stored and executed in the controller, and the controller-resident
database shall be viewable graphically on-line and uploadable to a PC or workstation without the
need for storing the “source” database off-line.
A. On-Line Tools
The configuration software shall provide on-line tools that assist in troubleshooting control
schemes. These tools must include on-line display of variables, the ability to force values and
states, support for on-line database changes, and on-line real-time trending.
It should be possible to display variables’ values and the status of ladder logic and SFC elements
while viewing an on-line controller database. The ladder logic and SFC element states shall be
indicated using colors.
The configuration software shall provide the ability to write values, states, and modes to
independent variables and elements in the controller. It shall also provide the ability to force non-
independent variables and elements to a predetermined value, state, or mode.
During troubleshooting, the user shall have the ability to stop the controller and single-step its
execution. This will provide a way to clearly understand complex configuration schemes and
highly interactive logic that might need to be examined.
B. Prebuilt Library of Functions
The configuration software shall include a predefined library of control schemes. The library must
include at least:
 Single PID loop with alarm

 Single PID loop with external setpoint and alarm
 Ratio control loop with alarm
 Cascade loop with alarm
 Primary control loop with alarm etc.
Separate, optional libraries should be available for specialized applications.

The configuration software shall also allow commonly used functions created by the user to be
added to a library for future use.
C. On-Line Help
On-line help screens in the configuration software shall be available to assist while creating a
database. The help screens shall include descriptions of every configuration element (e.g. each
function block and ladder logic element).
D. System Architecture
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A system architecture graphic depicting the hardware within the control system should be provided.
This graphic should give status information for the modules in the system by using colors to indicate
general health of the modules.
Windows Based Operator Software
The industrial-grade PC-based operator interface software shall be able to run on a personal
computer of the most current technology under Windows. The software shall provide all standard
operator functions, including process monitoring, alarm management, real-time and historical
trends, reports, plus provide process graphic displays, an integrated historian, Internet enabler,
batch manager and control simulator.
Reliability
The system must be designed for maximum reliability and minimal downtime. This should be
achieved through a fault-tolerant design with minimal common cause failures and state-of-the-art
redundancy schemes.
System shall offer highest possible MTBF within the service period of 15 + years is achieved. As
per DIN 40041, reliability is understood to be the "the property of an entity to fulfill its reliability
requirements during or after a given time span under given application conditions", therefore
concessionaire is required to assure the airconditioned environment of PLC system as stipulated in
Annexure provided as part of Scope of Works.as minimum requirement.
Controller
The controller must have a fault-tolerant design, with redundancy in the same model
Standard Fault Tolerance
The module communication bus and each I/O communication bus must be redundant. If one side
of a redundant bus should fail, communications should continue, uninterrupted, on the remaining
side of the bus.
The module rack shall provide two separate power supply modules, with each module capable of
drawing power from any of the two.
Operator Interface
Window based operator interfaces need to be supplied such that the failure of one component, card,
or module does not cause the operator to lose any portion of the process window.
Features Required in SCADA System
The system will be based on latest version of SCADA system. The main SCADA system will be
redundant. Based on application, servers are to be distributed with redundancy. For cyber security
it is proposed that security solutions shall be provided and separate DMZ zone be made so that
outside intrusion can be minimised. Network monitoring system shall also be provided for
monitoring of network devices. SCADA system will have many extra features and the proposed
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system should support multiple PLC/ RTU Protocol like Modbus, Profibus, DNP (Serial/TCPIP),
OPC etc.
5. Detailed functional Specification of RTOLMS System Components
5.1. Data Acquisition
The RTOLMS system shall perform data acquisition from PLC of all treatment plants, all LS / PS
and field equipment. PLC is to be located at each location of the treatment plant and LS/PS. PLC
communications with central system shall utilize the Open protocol like Modbus, Profibus and
Ethernet TCP/IP.
5.2. Data Exchange
The RTOLMS systems shall be able to exchange various types of data with the other application
software using ActiveX Data Objects (ADO) or Dynamic Data Exchange (DDE).
5.3. Data Processing
a) Analog data
Analog data processing shall be performed according to the requirements listed below.
- Conversion to measurable Units as required by ULB / {NATIONAL/STATE LEVEL

AGENCY IF ANY}
- Reasonability limits checking
- Limit monitoring
b) Digital/Status Input Data
The following status input data types shall be accommodated as a minimum: Two-state points:
The following pairs of state names shall be provided:
(1) Open/Closed
(2) Tripped/Closed
(3) Alarm/Normal
(4) On/Off
(5) Auto/Manual
(6) Remote/Local
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c) Calculated Data
It shall be possible to define the calculations on real-time data and historical data, periodically
and on request. The results shall be incorporated into the database as calculated data available
for display & report generation.
The user shall be able to define calculated analog values using database points as the arguments
and mathematical functions as the operations. Functions such as addition, subtraction,
multiplication, division, maximum value, minimum value, average, count, square root,
exponentiation, trigonometric functions, logarithms and other statistical functions shall be
provided.
The RTOLMS system shall be capable of analyzing the open/closed status of switching
devices, such as Motor, PUMP etc. The configuration shall be updated whenever a switching
device status change is detected.
5.4. Sequence-Of-Events Recording
The Sequence-of-events (SOE) data shall be collected by the RTOLMS system from PLCs. The
description of each event shall include the database description name, device state, the date, and
the time (to the nearest millisecond) of each event.
5.5. Supervisory Control

An authorized user of SCADA system shall be able to control the operation of field devices
connected to PLCs. A control action shall require a confirmation of selection prior to execution of
control command.
The user shall be able to select and operate any controllable switching device. Controllable
switching devices will be of like, Pump, Motor.
5.6. Information Storage and Retrieval
Information Storage and Retrieval (ISR) system shall collect and store analog data (telemetered
and calculated) periodically at every 5 minute (configurable) and status data by exception.
Associated quality codes shall be included. It shall be possible to perform calculations on the stored
data, and the results of these calculations shall be collected and stored. Other information such as
alarms, events, SOE and reports shall also be stored. The data shall be stored on hard disc with date
tag on daily basis for easy retrieval. Subsequently, the data shall be retrieved for analysis, display,
trending, and report generation.
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5.7. Extensive Use of Standard
The RTOLMS Software should be such that it uses an extensive use of standards, achieved by a
corporate commitment to comply with all standards that are recognized on the RTOLMS market,
and in particular:
- Intel (or compatible) based hardware;

- Operating system options of WNT 4.0, Windows should be of latest version as available
in the market and shall be compatible with SCADA equipment Library;
- Uses Microsoft Foundation Class (MFC) Object Oriented Database;
- Developed with Microsoft Developer’s Studio;
- Installed using Microsoft Install Shield utilities;
- Component Based Architecture;
- Interfaced using Active X controls (OCX);
- TCP/IP for Local and Wide Area Networks (LAN & WAN);
- Web-enabled Operator Consoles;
- Control Center Application Programming Interface (CCAPI) Initiatives
5.8. System Sizing & Extensibility
The hardware and software openness of RTOLMS allows the Executing Agency / concessionaire
to smoothly upgrade the proposed system with great facilities. Common upgrading needs include
(but not limited to) the following items:
- Additional measurement points (analog and digital);

- Additional protocol-compliant IEDs;
- Additional protocol-compliant PLCs;
- Additional operator consoles;
- Additional printers;
5.9. Graphical User Interface (GUI)
The GUI shall operate within a window environment, the system shall use displays which mimic
the existing control panels so that the operators working in conventional control room environment
are comfortable while working on the new system. Concessionaire shall develop control panel
display generally similar to the one existing in conventional control room.
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The GUI shall allow the personnel to monitor and control the equipment through the control panel
displays and Tabular displays. The control panel displays shall be dynamically updated for
measurands, device positions, annunciations. To have better visibility of control panels, it shall be
possible to iconise each control panel separately. Operator shall select that icon to zoom/view that
panel display & carry out operations such as alarm annunciation accept/reset, device close/open
operations etc.
5.10. Trending
Trend displays shall enable the user to select real-time and historical data for trending on graphical
displays and for tabular displays. It shall be possible to take print of these trends.
5.11. Alarms
Alarms are conditions that require user notification when detected. Audio, visual alarm shall be
generated for all such conditions. It shall be possible to accept & reset all trip & non-trip alarm
annunciation appearing on control panel facia from control panel display itself. Alarm annunciation
on control panel shall have following characteristics:
Condition Facia Sound

Alarm initiation by relay contact Flashing Glow On
Accept PB pressed Steady Glow Off
Reset Off (if relay contact is reset)
Steady Glow (if relay contact is not reset) Off
Other alarm conditions shall be acknowledged from respective alarm list displays. Other alarm
conditions shall include, but not be limited to the following:
(a) Telemetered or calculated value limit violations

(b) Un-commanded changes of a power system device state
(c) Data source communication errors resulting in loss of data
(d) SCADA hardware and software element failures.
The standard products for advanced alarm management shall also be provided. Regardless of the
alarm management technique used, all alarm messages shall be recorded with time & date tag on
auxiliary memory for review and printing on demand by the user.
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Displays shall highlight alarm condition using a combination of colour, intensity, inverse video and
blinking. Alarm messages shall be a single line of text describing the alarm that has occurred with
date & time of occurrence.
5.12. Events
Events are conditions or actions that shall be recorded by the SCADA system but do not require
user action. Events shall be recorded in the form of an event message. The event message format
shall be similar to the alarm message format. Events shall include but not be limited to the
following:
Values returning to normal from a limit violation State Device status change on manual operation.
5.13. Hardcopy Printing of Display
A means shall be provided to produce a copy of a display. The display printout shall be initiated
from user friendly push buttons/pull down menus. The options for printing mode shall include at
least selection for orientation, background colour, page size, colour or black & white print and print
preview. It shall also be possible to print selected portions of display and direct printing on any of
the connected printer.
5.14. Report Generation
The user shall be able to schedule periodic reports generation, direct a report to a display, print a
report, and archive a report. Hardcopy report formats shall be handed over to Concessionaire for
generation of report formats in the system. It shall also be possible to define and generate the
additional user configurable reports. The generation and printing of any report shall not effect
normal scanning of data from PLC. The report scheduling display shall enable entry of the
following parameters, with default values provided where appropriate:
(a) Report name

(b) Report destination (printer or archiving device)
(c) Time the system should produce the report.
5.15. RTOLMS System Access Security
A mechanism for defining and controlling user access to the SCADA system shall be provided.
5.16. Alarm Summary Displays
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Displays that list or summarize all unacknowledged and acknowledged alarms shall be provided.
The user shall be able to select between viewing alarms in chronological and reverse chronological
order. The default shall be most recent alarms. The summary shall separate acknowledged and
unacknowledged alarms. To facilitate identification of unacknowledged messages the time field
shall blink or entire row shall blink. It shall be possible to sort alarms by user defined text, date,
time.
5.17. Event Summary Displays
Event summary displays shall list the most recent events. The user shall be able to select between
viewing events in chronological and reverse chronological order. The user shall be provided with
a convenient and efficient means of selecting an event summary display. It shall be possible to sort
events by user defined text, date, time.
5.18. Operating Information Summaries
The operating information summaries defined below shall be provided. Summary items will be
listed in reverse chronological order with the most recent item shown on the first page. The user
shall have the ability to sort summary items by device.
5.19. Abnormal Summary
The summary display shall list devices and values that are found to be abnormal, i.e., are not in
their normal state. Telemetered, calculated, and manually entered status and data values shall be
included.
5.20. Out-Of-Scan Summary
The out-of-scan summary display shall list device status and data values that are not currently being
processed by the system.
5.21. Alarm Inhibit Summary
This display shall list devices and data values for which the user has suspended alarm processing.
5.22. Tag Summary
This display shall list and describe all active device tags.
5.23. Help Displays
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Help displays shall be provided to aid the user in interpreting displayed information and to guide
the user through a data entry or control procedure.
5.24. Alarm Beeper Services
The Alarm Beeper service audibly notifies the operator of recent alarms by playing a wave file.
Wave files can be used to distinguish between Alarm priorities. All the Windows’ .wav files or
customized wav files can be used.
5.25. Alarm Pager Services
The Alarm Pager service allows the user to configure the system to issue various pages in response
to specified alarms.
6. Instruments Power Supply and Signal Cables

a) Cables for power supply to instruments and Digital signals: shall be 660 V/1100 V
grade Multi-core cables, multi-stranded high conductivity, annealed 1 sq.mm
stranded tinned copper conductor, extruded PVC insulated with aluminum Tap. ATC
drain wire run continuously in contact with aluminum Mylar tap, inner sheathed with
extruded PVC, armored with galvanized steel wire, over all sheathed with extruded
PVC, confirming to IS:1554 & IEC-189 part II.
b) Cables for Analog signals and signals from temperature sensors: 660 V/1100 V
grade multicore cables, multi-stranded high conductivity, annealed 1 sq.mm
stranded copper conductor, extruded PVC insulated two/three cores twisted in to
pair/triad laid up collectively, individual in pair/triad shielded and overall shielded with
aluminum Mylar tap. ATC drain wire run continuously in contact with aluminum side
of tap, inner sheathed with extruded PVC, armored with galvanized steel wire, over
all sheathed with extruded PVC, confirming to IS:1554 & IEC-189 part II.
c) Instrumentation cable in between conventional measuring transmitters and analogue process

controllers, such as digital or 4mA to 20mA DC output from a constant current source.
d) Cables from indicating devices to alarm or tripping circuits shall be as specified

above for high level signals but shall use cables, cable trays, ducts and conduit
separate from those for other high-level circuits.
e) Cables for high-level signals, low-level signals, resistance thermometers and

thermocouples shall be segregated from each other and each shall be separated
from cables for power, communications and other electrical services.
f) Other cables running in the vicinity of instrumentation cables shall be twisted at the
rate of one twist per 50mm approximately and shall be separated from
instrumentation cables by a distance of not less than 300mm.
g) Initiating devices for plant protection and personnel safety shall be connected by
individual cables directly to the tripping or safety device and shall not be routed via
any intermediate junction, Marshaling box, cabinet, relay etc. The outer sheaths of
such cables shall be orange colored.
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h) Cables shall be capable of satisfactorily withstanding without damage, transportation to site,
installation at site, and operation under normal and short circuit conditions of the various systems
to which the respective cables are Connected when operating under the climatic conditions
prevailing at the site as indicated in this specification.
i) Cable joints in instrument signals and power supply cables shall not be permitted.
j) Cables shall be capable of satisfactory performance when laid on trays, in trenches, conduits,
ducts and when directly buried in the ground.
k) Cables shall be capable of operating satisfactorily under a power supply system voltage
variation of ±15%, a frequency variation of ±5.0% .
Laying of cables
a) A distance of minimum 300mm shall be maintained between the cables carrying low voltage
AC and DC signals and a distance of minimum 600mm shall be maintained between cables
carrying HT and LT signals. In outdoor areas, the cables shall be directly buried. Each
instrumentation and power supply cable shall be terminated to individual panel/ terminal box.
Identification of each cable shall be by proper ferrules at each junction as per cable schedule to be
prepared by Concessionaire.
b) Cables shall be laid in accordance with layout drawings and cable schedule which shall be
prepared by Concessionaire and submitted for Engineer's Representatives approval.
c) All cable routes shall be carefully measured and cables cut to the required lengths, leaving
sufficient amount for the final connection of the cable to the terminals on either end. Various cable
lengths cut from the cable reels shall be carefully selected to prevent undue wastage of cables. A
loop of 1 meters shall be left near each field instrument before terminating the cable.
d) Cables shall be complete uncut lengths from one termination to the other.
e) All cables shall be identified close to their termination point by cable numbers as per cable
interconnection schedules. Identification tags shall be securely fastened to the cables at both the
ends.
f) Cable shall be rigidly supported on structural steel and masonry, using individually cast or
malleable iron galvanized clips, multiple cable supports or cable trays.
7. Cable Trays for Instrumentation & Automation
Refer Electrical section for details for Instrumentation and Automation system
Cable trays and accessories
8. Wireless Communication System (GSM / GPRS)
GSM/GPRS Based wireless communication system shall be provided for each pump house (IPS-
MPS), STP and Main Control Room. GSM/GPRS System shall be provided
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with all mounting accessories
GSM/GPRS Details
Input RS-232/485 through PLC System

Power Supply 240 AC/ 24 VDC
Memory& Storage As per system requirement
Modem Type Dual Sim Type
Antenna Required
617
Section G5.6
Inspection and testing at manufacturer’s works
618
Section G5.6 : Inspection and testing at manufacturer’s works
All inspection and testing shall be carried out in accordance with the standards and Specification
and in absence of Specification relevant Indian Standard or internationally approved equivalent
standard. After award of contract, Concessionaire shall furnish QAQC plan, which will be
mutually discussed with the Executing Agency and finalized QAQC plan shall include tests on
incoming supply of raw materials and bought out items, stage inspections and tests on finished
products at manufacturer's works / appropriate testing station. QAQC plan shall clearly indicate
tests which are intended to be witnessed by the Concessionaire alone and those by both
Concessionaire and Project Engineer and Executing Agency.
The Concessionaire shall carry out wherever practical, at the place of manufacture tests of the Plant
/ Equipment.
The Executing Agency shall be entitled to attend the aforesaid inspection and / or tests by his own
duly authorized and designated representatives.
The Executing Agency and his duly authorized representative shall have access to the
Concessionaire's premises at all suitable times to inspect and examine the material and
workmanship of the mechanical and electrical plant and equipment during its manufacture there. If
part of the plant and equipment is being manufactured on other premises, the Concessionaire shall
obtain permission for the Executing Agency or his duly authorized representative, to inspect as if
the plant and equipment was manufactured on the Concessionaires own premises. Testing
(including testing for chemical analysis and physical properties) shall be carried out by the
Concessionaire and certificates submitted to the Executing Agency who will have the right to
witness or inspect the above mentioned inspection / testing at any stage desired by him. Where
inspection or testing is to be carried out at a sub-contractor's works, a representative of the
Concessionaire shall be present.
The procedure for the testing and inspection to be carried out during or following the manufacture
of the materials to ensure the quality and workmanship of the materials and to further ensure that
they conform to the Contract is whatever place they are specified shall be as described below.
The Concessionaire shall give the Executing Agency at least 21 clear days’ notice in writing of the
date and the place at which any plant or equipment will be ready for inspection/testing as provided
in the Contract. The Executing Agency or his duly authorized representative shall thereupon at his
discretion notify the Concessionaire of his intention either to release such part of the plant and
equipment upon receipt of works test certificates or of his intention to inspect. The Executing
Agency shall then give notice in writing to the Concessionaire, and attend at the place so named
the said plant and equipment which will be ready for inspection and/or testing. As and when any
plant shall have passed the tests referred to in this section, the Executing Agency shall issue to the
Concessionaire a notification to that effect.
The Concessionaire shall forward to the Executing Agency duly certified copies of the test
certificates and characteristics performance curves for all equipment.
If the Executing Agency fails to attend the inspection and/or test, or if it is agreed between the
parties that the Executing Agency shall not do so, then the Concessionaire may proceed with the
inspection and/or test in the absence of the Executing Agency and provide the Executing Agency
with a certified report of the results thereof as mentioned above
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If any materials or any part of the works fails to pass any inspection / test, the Concessionaire shall
either rectify or replace such materials or part of the works and shall repeat the inspection and/or
test upon giving a notice as mentioned above. Any fault or shortcoming found during any inspection
or test shall be rectified to the satisfaction of the Executing Agency before proceeding with further
inspection.
Where the plant and equipment is a composite unit of several individual pieces manufactured in
different places, it shall be assembled and tested as one complete working unit, at the maker's works
or at site as mutually agreed by the Executing Agency and Concessionaire.
Neither the execution of an inspection test of materials or any part of the works, nor the attendance
by the Executing Agency, nor the issue of any test certificate shall release the Concessionaire from
any other responsibilities under the Contract.
The test equipment, meters, instruments etc., used for testing shall be calibrated at recognized test
laboratories at regular intervals and valid certificates shall be made available to the Executing
Agency's at the time of testing. The calibrating instrument used as standards shall be traceable to
National / International standards. Calibration certificates or test instruments shall be produced
from a recognized Laboratory for the Executing Agency's consent in advance of testing and if
necessary instruments shall be recalibrated or substituted before the commencement of the test.
Items of plant or control systems not covered by standards shall be tested in accordance with the
details and program agreed between the Executing Agency and Concessionaire.
Tests shall also be carried out such that due consideration is given to the Site conditions under
which the equipment is required to function. The test certificates shall give all details of such tests.
The Concessionaire shall establish and submit a detailed procedure for the Inspection of materials
or any part of the works to the Executing Agency for approval within the date indicated in the
Program Details. The detailed procedure shall indicate or specify, without limitation, the following:
i) Applicable code, standard and regulations

ii) Fabrication sequence flow chart indicating tests and inspection points
iii) Detailed tests and inspection method, indicating tests and inspection points
iv) Acceptance criteria
v) Test report forms and required code certificates and data records
vi) Method of sampling, if any sampling test to be conducted
vii) Concessionaire's or Executing Agency's witness points.
The Concessionaire shall not pack for shipment any part of the Plant until he has obtained from the
Executing Agency or his authorized representative his written approval to the release of such part
(Dispatch Clearance, which will be provided by Executing Agency after submission of test reports
by the Concessionaire) for shipment after any tests required by the Contract have been completed
to the Executing Agency's satisfaction.
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Part-C
Testing and Commissioning
621
Part C
Testing and Commissioning
Requirements Inspection and Testing During Construction
1.1 General
Inspection and testing of all Facilities shall be carried out in accordance with the relevant Indian
Standard or internationally approved equivalent standard. QA plan shall clearly indicate tests
which are intended to be witnessed by the Concessionaire alone and those by Concessionaire and
Executing Agency & Project Engineer.
Inspection and tests schedule shall be as follows;
(i) Manufacturer tests

(ii) Acceptance Inspection / Quantitychecking
(iii) Install /Site Inspection
(iv) Site AcceptanceTest
(v) Tests on Completion
(vi) Process Wet Tests (by Raw Sewage)
(vii) Operation Test (Tests After Installation)
The Concessionaire shall establish and submit a detailed procedure for the inspection of materials
or any part of the Facilities to the Project Engineer and Executing Agency for approval within the
date indicated in the Program Details. The detailed procedure shall indicate or specify, without
limitation, the following:
 Applicable code, standard, andregulations.

 Fabrication sequence flowchart indicating tests and inspection points.
 Detailed tests and inspection method, indicating the measuring apparatus to be used, items
to be measured, calculation formula, etc.
 Acceptance criteria.
 Test report forms and required code certificates and datarecords.
 Method of sampling, if any sampling test to be conducted.
 Concessionaire’s or Project Engineer’s/Executing Agency’s witnesspoints.
The witness testing shall be carried out for all the Mechanical, Electrical, Instrumentation, PLC,
SCADA and Associated Equipment at the Manufacturer’s works as per approved QA Plan and all
622
the costs associated with such testing (including all testing charges, test material for NDT,
travelling, lodging etc. for Executing Agency’s & Project engineer’s representatives etc.) shall be
borne by the Concessionaire.
1.2 Testing on Construction Completion
For all the subject Facilities, prior to the commencement of Trial Operations on respective
Construction Completion the Concessionaire shall submit the following to the Executing
Agency:
(1) As-Built Drawings for STP, Network and Pumping stations (MPS/SPS/IPS/LS)
(2) Operation and Maintenance Manuals for all facilities (STP, associated infrastructure i.e.
MPS and Network)
(3) Site test results (mandatory test required during construction phase and cahracteristics of
inlet and outlet of sewage water)
Without submission of above documents, COD will not be declared by UPJN.
The initial charges of oil, grease, generator fuel / oil, chemical, disposal of cake, etc. necessary
for Trial Operation shall be borne by theConcessionaire.
a) Manual Commissioning Tests
Manual commissioning tests shall be such preliminary trials, tests and retests on subject
Facilities prior to subject Facilities COD respectively, in order to demonstrate that the subject
Facilities as a whole are ready to undergo the manual operation tests and that these will take
place with a minimum of interruption.
b) Manual OperationTests
When the manual commissioning tests have been completed so that the subject Facilities have
been demonstrated to the satisfaction of the Project Engineer and Executing Agency, the
Concessionaire shall commence the manual operation tests.
These tests shall demonstrate the correct operation of the subject Facilities whilst using the
minimum quantity of automatic control and monitoring equipment. Such equipment shall be
at least that required for the maintenance of safety and for the normal mode of operation of
such Facilities.
623
The subject Facilities will be required to demonstrate satisfactory operation at all design flow
rates.
c) Automatic Commissioning Tests
The Automatic Commissioning Tests shall be such preliminary trials, tests and retests on
subject Facilities in order to demonstrate that the subject Facilities as a whole ares ready to
undergo the tests of completion and that these will take place with a minimum of interruption.
1.3 Dry Test Requirements
As a minimum requirement the following dry tests shall be carried out as a general requirement:
(1) A general inspection to check for correct assembly and quality ofworkmanship
(2) A check on the presence of lubricant, cooling medium, electrolyte, etc.
(3) A check on adequacy and security of Facilities fixing arrangements.
(4) A general check to ensure that all covers, access ladders, water proofing, guard railings etc.
are in place.
(5) A check on damp-proofing, rust-proofing and vermin-proofing and particularly the sealing
of apertures between building structures, chambers etc. and the outside.
a) Civil and BuildingWorks
As a minimum requirement, check for the presence of foreign bodies in pipe work and
structures shall be carried out on the civil and building works.
b) MechanicalWorks
As a minimum requirement, preliminary leveling, alignment, running checks as far is

permitted by circumstances in order to ensure smooth operation of Facilities shall be carried
out on the mechanical systems.
c) ElectricalWorks
624
As a minimum requirement the following dry tests shall be carried out on the electrical
systems:
a. Check phasing and polarity.
b. Carry out point to point check oncables.
c. Check on security of cableterminations.
d. Check on completeness and adequacy of earthing systems.
e. Check setting on protection relays, sizes of fuses and motor overload settings.
f. Carry out checks on cabling systems in accordance with the requirements of the relevant
standards.
g. Check operation of main circuit breakers by secondary injection methods.
h. Check rotational direction ofPlant.
i. Check instrument loop integrity, functionality and calibration.
j. Check operation of standby generator installation and mains / generator changeover
procedures; a 4 hour load test (using the normal load of the Works) shall be carried out
on the generator when the load is available.
k. Check plant functionality.
l. Check functionality of the central MMI and its power supply.
1.4 Process plant item /equipment
All process plant items / equipment shall be tested to ensure they meet the requirements for quality
of workmanship, construction and performance as laid down in the Concession Agreement.
1.4.1 Hydraulic Wet TestRequirements
Hydraulic wet tests shall be carried out on completion of dry tests.
Clear water shall be used for hydraulic wet tests. The purpose of the tests is to prove the hydraulic
performance of the Works. In order to demonstrate this, the Concessionaire shall ensure that each
part of the Works is hydraulically loaded to its rated throughput for a period of at least four hours.
In order to ensure a sufficient supply of water to carry out these tests the Concessionaire shall
provide all required facilities, including but not limited to any temporary facilities that may be
required for storage and recycle of clear water or facilities for the disposal of the water off Site in
an approved manner.
625
The following tests inter alia shall be carried out:
(i) Pressure testing of all piped systems laid direct in ground in accordance with the relevant
standards.
(ii) Fill all structures and check for leaks.
(iii) Filling of all storage vessels to check for leaks and distortion.
(iv) Running of all pumped systems in order to check for functionality and leaks.
(v) Correct functionality.
(vi) Absence of leaks.
(vii) Correct runningtemperatures.
(viii) Smoothness of running and the absence of undue vibration or stress.
(ix) Check drive running currents.
(x) Carry out calibration of instruments where appropriate.
(xi) Carry out valve operation, diversions etc. to fully hydraulically load each process element
(or where there is a requirement to withstand an over load), overload each process
element.
(xii) Demonstrate correct functionality of electrical, control and instrumentation systems.
1.4.2 Process Wet Tests (with Raw Sewage)
On approval by the Project Engineer the Concessionaire shall carry out process wet tests.
Raw Sewage shall be used as the primary feed stock for process wet tests. These tests shall be
carried out to demonstrate the process performance of the Works. In order to demonstrate this, the
Concessionaire shall ensure that each part of the Works is loaded to its rated throughput (including
a period of overload if required in order to demonstrate compliance with the Project Engineer’s
Requirements) for a continuous stable operating period of not less than 48 hours.
The Concessionaire shall provide all required facilities for the disposal off Site in an approved
manner. The following tests interalia shall be carried out:
(i) Check for leaks on vessels, structures, pumps and pipework.

(ii) Running of all pumped systems in order to check for.
 Correct functionality.
 Absence of leaks.
 Correct running temperatures.
 Smoothness of running and the absence of undue vibration or stress.
626
 Check drive running currents where the solution pumped is different from that
pumped during hydraulic wet tests.
(iii) Carry out calibration ofinstruments.
(iv) Carry out valve operation, diversions etc. to fully hydraulically load each process element
(or where there is a requirement to withstand an overload), overload each process element.
(v) Demonstrate correct functionality of electrical, control and instrumentation systems not
checked during dry or hydraulic wet tests or which may have changed as a result of the
different operating conditions now prevailing.
On completion of the tests on the various parts of the works the Concessionaire shall run all subject
Facilities as a whole in order to demonstrate the full functionality and performance of the subject
Facilities at various throughput rates for a continuous period as specified in Concession
Agreement.
1.5 Trial Operations
The Trial Operations shall be used to prove the operation of the subject Facilities are in
compliance with the KPIs at varying flows and with varying Influent Standards.
1) The quality of Treated Effluent produced
2) Guaranteed Energy Consumption
3) Quality of Digested Sludge
4) The quality of Treated Water produced
Raw Sewage shall be used as the main feed stock for Trial Operations. These tests shall be carried
out to demonstrate the process performance of the Facilities. In order to demonstrate this, the
Concessionaire shall ensure that each part of the Facilities are loaded to rated throughput.
The following tests, inter alia, shall be carried out:
(1) Check for leaks on vessels, structures, pumps and pipework.

(2) Running of all pumped systems in order to check for.
✓ Correct functionality.
✓ Absence of leaks.
✓ Smoothness of running and the absence of undue vibration or stress.
✓ Check drive running currents where the solution pumped is different from that pumped
during hydraulic wet tests.
(3) Carry out calibration of instruments.
627
(4) Carry out valve operation, diversions etc. to fully hydraulically load each process element
(or where there is a requirement to withstand an overload), overload each process element.
(5) Demonstrate correct functionality of electrical, control and instrumentation systems not
checked during dry or hydraulic wet tests or which may have changed as a result of the
different operating conditions now prevailing.
1.6 Trial Operation & minimum performance standards testrecord
The Concessionaire shall maintain two copies of Trial Operation test reports for documentation
of the following information on daily basis.
 Print outs of data logs from SCADA system.

 Samples collected for assessment the quality of Treated Effluent
 Samples collected for assessment the quality of Treated Water
 Electricity consumption.
 Stabilized Digested Sludge characteristics
Log sheets required for noting down readings / results of various tests shall be prepared.
628
PART D
Specifications for Operation and Maintenance
629
Part D : Specifications for Operation and Maintenance
1.1. General
The STP Facilities and Associated Infrastructure shall run 24 hours every day and 365 days each
year continuously under normal operation.
1.2. The O&M manual
The Concessionaire shall submit an O&M Manual as per the Concession Agreement before 90 days
of COD. The O&M of the STP Facilities and Associated Infrastructure shall be done as per the
approved O&M Manual, any approved updations to it as agreed by the Executing Agency and the
ESHS Plan.
1.3. Guidelines of operations
1.3.1. Inventory control
Throughout the O&M Period, the Concessionaire shall provide and maintain tools and spare parts
in accordance with the Concession Agreement.
The current stock levels shall be updated on-line by monitoring signals of the SCADA system (e.g.
level of chemical tanks). All delivery of spare parts and consumables shall be recorded as
appropriate.
The Concessionaire shall carry out inventory checks every six months. The inventory checks shall
be scheduled to avoid disturbance to the O&M.
1.3.2. Chemicals, Dangerous Goods and Hazardous Materials
The Concessionaire shall provide and maintain storage of chemicals, dangerous goods and
hazardous materials required for the O&M. Dangerous goods include any of the goods or
substances to which the Dangerous Goods Ordinance applies.
1.4. Guidelines for Maintenance
The Concessionaire shall carry out corrective and preventive and scheduled maintenance of the
Facilities and Associated Infrastructure in accordance with the Design and Drawings, O&M
Manual, Scheduled Maintenance Program and ESHS Plan to ensure the facilities and equipment
perform to the specific standards.
The maintenance of all civil structures shall be done for a period of 15 years as per the frequency
as per CPWD maintenance manual 2019 or latest publication as approved by Executing Agency.
630
1.5. Maintenance Management
A Computerized Maintenance Management System (CMMS) shall include functions for the
creation and upkeep of work orders and maintenance records. The database shall include the
following information:
o Preventive maintenance programs of systems, equipment, building and infrastructure of

the Facility, which are used to generate work orders for preventive maintenance
automatically;
o Logs of system or equipment fault / breakdown and automatic generation of work orders
for corrective maintenance;
o Date of inspection / maintenance (preventive or corrective) carried out;
o Names and positions of Concessionaire’s staff carried out the inspection / maintenance;
o Logs of manual alterations of any operations records, etc;
o Details of inspection / maintenance carried out including:
 Causes of maintenance
 Maintenance procedures
 Special gears / equipment used
 Spare parts used
 Equipment / parts replaced
 Any follow-up actions / recommendations (e.g. change of operational procedures, etc.)
The CMMS shall have functions to organise, sort and filter the maintenance records in the database
as required and perform statistical analysis and generate reports for performance monitoring. The
CMMS database shall be archived on a monthly basis. One electronic copy of the entire database
shall be stored on the Site for retrieval as necessary.
1.5.1. Calibration of Instruments and Measuring Equipment
The Concessionaire shall maintain accuracy and reliability of all measurement facilities throughout
the O&M Period to enable correct and effective monitoring and control of the Facilities and
Associated Infrastructure. As per equipment manufacturer Instruction Manual and as per latest
CPCB guideline
The Concessionaire shall be responsible for the calibration and re-calibration as necessary of all
measurement facilities. All calibration work shall be carried out so as not to delay or disrupt the
O&M. Calibration frequency shall not be less than that recommended by the manufacturers of the
instruments or measuring equipment and in any case no longer than 12-month intervals.
1.5.2. Tools and Spare Parts
631
During the O&M Period, the Concessionaire shall provide and maintain tools and spare parts in
accordance with the Concession Agreement.
The storage of special tools and inventory of spare parts shall be recorded and monitored.
At the expiry of the O&M Period, the Concessionaire shall handover to the Executing Agency all
special tools and spare parts in accordance with the Concession Agreement. The stock level of
spare parts shall be sufficient for 1 year operation from the end of the Concession Term.
1.6. Records and Reporting
1.6.1. Archiving of SCADA and CMMS Data
The Concessionaire shall maintain all operation and maintenance records, including SCADA,
throughout the O&M Period in a safe and secure manner. Any amendment to the records shall only
be made in accordance with proper checking and authorization procedures, which shall be included
as part of the O&M Manual.
The Project Engineer shall be allowed to check the above mentioned data and records described at
any time.
As far as possible, all records shall be kept electronically utilizing the Concessionaire’s computer
facilities with backup security. If the computer facilities fail, then appropriate paper records shall
be produced and filed.
1.6.2. Site Diary
The Concessionaire shall maintain a Site Diary which shall include, as a minimum, the following
information on a daily basis:
o Date and weather;

o Operation hours;
o Labour on the Site;
o Flow and quality records of influent and effluent;
o Disposal records of treatment by-products;
o Accidents and incidents;
o Instructions to the Concessionaire;
o Comments by the Concessionaire;
o Complaints received and action taken;
o Authorized visitors to the Site; and
The Site Diary shall be checked and signed by authorized personnel of the Concessionaire in
accordance with the O&M Manual.
632
The Concessionaire shall keep appropriate records of all personnel employed at the Site. These
records shall be available for inspection by the Project Engineer at any time.
1.6.3. Safety and Health Records
The Concessionaire shall keep records on all safety and health matters as per the requirements of
the Concession Agreement, O&M Plan and the EHS Plan and update such records daily for
inspection by the Project Engineer.
1.6.4. Daily report
The Concessionaire shall provide details in the form of daily reports, of operational data and
information in relation to the O&M of the Facilities to the Executing Agency in a systematic and
concise manner, which shall include the following. The frequency of testing must as per the
Table:Testing Methodology and Frequency
o Availability of the Facilities

o Characteristics of the Treated Effluent and deviations from the KPIs, if any
o Characteristics of the Digested Sludge and deviations from the KPIs, if any
1.6.5. Monthly Report
The Concessionaire shall provide details in the form of monthly reports, of operational data and
concise manner. Monthly reports shall be submitted to the Executing Agency by the 7th day of the
subsequent month and shall include the following:

o Summary of energy consumption (fuel and electricity) of the Facility;
o Quantities of chemicals, reagents, fuel and spare parts consumed;
o Stock level of chemicals, reagents, fuel and spare parts;
o Program showing the scheduled maintenance (including planned and ongoing) work in the
following month.
1.6.6. Quarterly Report
The Concessionaire shall provide details in the form of monthly reports, of operational data and
concise manner. Quarterly reports shall be submitted to the Executing Agency within 7 days of end
of a quarter and shall include the following:
633
o Summary of energy consumption (fuel and electricity) of the Facility;
o Quantities of chemicals, reagents, fuel and spare parts consumed;
o Stock level of chemicals, reagents, fuel and spare parts;
Program showing the scheduled maintenance (including planned and ongoing) work in the following
quarter.
1.6.7. Annual Report
The Concessionaire shall submit Annual Reports to the Executing Agency within 30 days of end
of the year and the report shall include the following:
o Summaries of quantities and characteristics of Sewage received and treated at the STP
during the reporting year;
o Overall performance of the STP with highlights on non-compliance with KPIs as reported
in each quarter;
o Summary of expiry dates for licences, permits and certificates for the O&M;
o Summary of major equipment breakdown, repair, overhaul, renewal, replacement,
modification, performance tests, condition surveys carried out;
o Summary of incidents related to safety and health, environmental issues, security and
complaints;
o Scheduled maintenance, overhaul, renewal, replacement, modification of major plant and
equipment, Performance Tests and Condition Surveys in the forthcoming 12 months;
o List of Changes ordered by the Executing Agency, with details and status;
1.6.8. Monthly Environmental Monitoring Report
The Concessionaire shall submit Monthly Environmental Monitoring Reports to the Executing
Agency providing overview of compliance with ESHS Plan.
1.6.9. Testing Methodology and Frequency
The raw sewage and treated effluent shall be tested and checked for compliance with KPIs as
defined below.
Parameterstobemeasured Frequency Methodology

Raw sewage and treated effluent It should be every Analysing the average of periodical values at every
(pH ,TOC based BOD & COD, 2 hours 5 minutes (configurable) and status data by
634
Parameterstobemeasured Frequency Methodology
TSS, TP, TN and Residual exception of respective online instruments /
Chloride analyzers
Raw sewage and treated effluent One composite 24-hour composite be collected and analysed.
(pH ,BOD,TSS, COD, TP, TN sample a day These samples shall be stored in a refrigerator at a
and Fecal Coliform) temperature between 1°C and 4°C. The sample
shall not be allowed to freeze.
Raw sewage and treated effluent One Composite The sample shall be tested in National
(pH ,BOD,TSS,COD, TP, TN sample of a day Accreditation Board for Testing and Calibration
and Fecal Coliform) every month Laboratories (NABL) accredited laboratory
recognized by CPCB and SPCB.
Digested / dewatered Sludge
Outlet Concentration of At time of Seven samples of sludge shall be collected at the
dewatered sludge , and volatile disposal or every time of disposal and analyzed for Outlet
suspended solids month concentration of dewatered sludge, and volatile
suspended solids,. The geometric mean of the
Outlet concentration of dewatered sludge, and
volatile suspended solids of these seven samples
shall not exceed the prescribed standards/ limits as
mentioned in the KPI.
Fecal coliform, Salmonella, At time of Seven samples of sludge shall be collected at the
viruses and helminth egg disposal or every time of disposal and analyzed for faecal coliforms.
month The geometric mean of the the seseven samples
shall notexceed the fecal coliform limits.
Outlet Concentration of Once in month The Outlet Concentration of dewatered sludge,
dewatered sludge, Fecal volatile suspended solids, and fecal coliform of any
coliform, Salmonella, viruses one sample every month shall be tested in National
,helminth egg and volatile Accreditation Board for Testing and Calibration
suspended solids. Laboratories (NABL) accredited laboratory
recognized by CPCB and SPCB
1.6.10. Staffing
For all operation and maintenance works, the Concessionaire shall provide skilled staff which has
adequate qualifications and sufficient experience of similar works.
The Concessionaire shall appoint an overall Facilities Manager to be responsible for managing the
Operation of the Facilities. The detailed staffing schedule shall be approved by Executing Agency.
No staff / labour below the age of 18 years shall be employed. The Concessionaire shall make
appropriate arrangements for maintenance of items like road work, buildings, horticulture,
635
patrolling and maintenance of civil structures, vehicle operations and other activities defined to
fulfill its obligations under O&M Contract.
The specifications laid down in the CPHEEO Manual for Operation and Maintenance shall apply till
handing over of the plant by the concessionaire to Jal Nigam/Saharanput Nagar Parishad or the agency
suggested by the Govt.of U P.
636
PART E
Electrical Load List
637
Part E1: List of Electrical Drives for Saharanpur STP
This information requested is to consider the Concessioanire load calculations for assessment of Emergency Load requirement. The Concessionaire shall include any particular additional equipment anticipated for the running of the facilities. The
Concessionaire shall fill in the requisite information as per the technology considered.
Sl. DESCRIPTION QTY. W S q = flow h = Ph = q ρ g η = Ps = Ph Motor motor KW of the KW of Type of V DUTY Total Total energy LOAD correct KW KVA
capacity h / (3.6 /η Motor feeder HOURS consumption FACTOR INPUT
No differenti 6
10 ) driven efficiency KW with Motor / KW per day, kWH ed P.F. ABSRBE
(m3/h) machine(pump, relevant
. al head blower etc.) margin Unit D
selected
(m) g = gravity efficien cy Ps =
(9.81 m/s2) shaft (each)
ρ = density power
of fluid (kW)
(kg/m3)
STP
1. Fine Screens
2. Conveyor System
3. Grit removal and

washing system
4. Primary Clarifier
Mechanism
5. Primary Sludge
Pumps
6. Scum pumps
7. Mixers in Anoxic
Tank
8. Air Blowers
9. EOT for Blowers
10. Secondary
Clarifier
Mechanism
11. Return Activated

Sludge Pumps
638
12. Waste Activated
Sludge
13. Decanters ( If
SBR provided)
14. Motorized Gates

& Valves
15. Thickened Sludge

Pumps
16. Dilution Water

Pumps
17. Digester Feed

Pumps
18. Digester Mixers
19. Air Compressor
20. Biogas Scrubber
21. Dewatering
equipment Feed
Pumps
22. Dewatering
equipment
23. Poly dosing

Agitator
24. Poly dosing

Pumps
25. Centrate return

Pumps
26. Plant Water

Pumps
27. Analytical
Instruments
28. Lighting and
Miscellaneous
Works
639
29 Disinfection
System
30. Any other

equipment
anticipated by
Concessionaire
640
Part E2: List of Electrical Drives for Pumping station
This information requested is to consider the Concessionaire load calculations for assessment of Emergency Load requirement. The Concessionaire shall include any particular additional equipment anticipated for the running of the facilities. The
Concessionaire shall fill in the requisite information as per the technology considered.
Sl. DESCRIPTION QTY. W S q = flow h = Ph = q ρ g η = Ps = Ph Motor motor KW of the KW of Type of V DUTY Total Total energy LOAD correct KW KVA
capacity h / (3.6 /η Motor feeder HOURS consumption FACTOR ed P.F. INPUT
No differenti 6
10 ) driven efficiency KW with Motor / KW per day, kWH ABSRBE
(m3/h) machine(pump, relevant
. al head blower etc.) Unit D
margin selected
(m) g = gravity efficien cy Ps = (each)
(9.81 m/s2) shaft
ρ = density power
of fluid (kW)
(kg/m3)
Pumping Station
1. Raw sewage
pump
2. Screens &
Conveyor system
3. Motorized Gates
4. Electrical hoist
5. Valves
6. Lighting and
other
miscellaneous
loads.
7.
8.
9.
10.
11.
12.
641
Schedule 11: Site Maps
1. Map representing Saharanpur (Old) STP Site and area available for development of
Saharanpur STP
642
Schedule 12: Discharge Point
STP location Discharge Point

Sr. No. Name
Degree, Minutes and Seconds Degree, Minutes and Seconds Comments
Proposed STP
at Dhamola
1 29°56'09.7"N 77°33'16.1"E 29°56'04.0"N 77°33'14.9"E River Saharanpur STP 135 MLD
(Saharanpur)
643
Schedule 13: Termination Compensation
In case of termination of the Agreement for a Concessionaire Event of Default, the Capex Annuity
payable as termination compensation under Clause 18.1(b), Clause 18.2(b) and Clause 18.3(b) will be
in accordance with the table below:
Termination in Year post relevant COD % of Capex Annuity

1 65
2 65
3 65
4 70
5 70
6 70
7 75
8 75
9 75
10 80
11 80
12 80
13 85
14 85
15 85
Signature Not Verified

Digitally signed by Praveen Kutti
Date: 2022.11.23 21:11:30 IST
Location: Uttar Pradesh-UP
644

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SCHEDULE I

A. Design, finance, development, construction, completion, 15 years operation and maintenance

Provide the following at Saharanpur STP:

xxvii. Soil erosion control measures at proposed stp site

Details of sewer Network

S.No Diameter Length (meter) Material of Pipe

2 Swami dental clinic* 0.5

8 Ram tirath school Drain (left side of Paondhoi)* 0.58

9 Kotwali nalla* 0.45

Main pumping station/SPS/IPS/LS STP I&D &

Liquid flow Inlet flow

Electrical parameter Voltage, Current,

• Site manpower and labor mobilization details. Details of project management

• Description of Proposed Technology including proposed treatment process,

Phase I Designs and Drawings (to be submitted for effectiveness)

Detailed construction drawings

• Design data sheets for equipment’s of all facilities being

• Detailed design calculations of foundations and superstructure

• Power single line diagrams

o Manufacturer’s catalogues and data sheets

o Manufacturer’s works tests

• Pump head calculation of all facilities being developed

• Detailed design calculations of foundations and superstructure

• Power single line diagrams

o Manufacturer’s catalogues and data sheets

o Manufacturer’s works tests

• Operational Contingency Plan

• Scheduled Maintenance Program for the first year post COD

[ON APPROPRIATE STAMP PAPER]

(3) [________________[insert name of the Concessionaire], a company organized, incorporated,

1. DEFINITIONS AND INTERPRETATION

Annexure means an annexure to this Substitution Agreement.

Arbitration has the meaning ascribed to it in Clause 8.2.

Article means an article of this Substitution Agreement.

Clause means a clause of this Substitution Agreement.

Company means a company incorporated under the Companies Act or a foreign

Concession has the meaning ascribed to it in Recital C.

Concessionaire means a Concessionaire Event of Default as defined under the

Dispute means any difference or dispute of whatsoever nature relating to this

Financing means, collectively, the documents entered into or to be entered into

Indemnified Party has the meaning ascribed to it in Clause 7.2.

Indemnifying has the meaning ascribed to it in Clause 7.2.

Notice of Dispute has the meaning ascribed to it in Clause 8.1.

Notice of Financial has the meaning ascribed to it in Clause 3.2(a).

Person means any individual, company, corporation, partnership, joint

Project has the meaning ascribed to it in Recital B.

Proposal shall have the meaning ascribed to it in Clause 4.1(c).

Selectee means a new Company proposed by the Lenders pursuant to this

Substitution has the meaning ascribed to it in Clause 3.3(c).

Substitution has the meaning ascribed to it in Clause 3.2(b).

In this Substitution Agreement, unless the context otherwise requires:

3. SUBSTITUTION OF THE CONCESSIONAIRE

3.1. Right of Substitution

3.2. Procedure in case of a Financial Default

3.3. Procedure in case of a Concessionaire Event of Default

4.2. Waiver of Concessionaire's Right to Remedy

7.2 Notices and Contest of Claims

8.1 Amicable Settlement

8.2 Dispute Resolution by Arbitration

8.3 Place of Arbitration

The place of the Arbitration shall be New Delhi.

8.4 English Language